LOGAN Uputstvo

1
Engine and assembly

10A
lower
engine
ENGINE AND LOWER ENGINE ASSEMBLY TOP AND FRONT OF ENGINE FUEL MIXTURE FUEL SUPPLY ANTIPOLLUTION STARTING - LOAD IGNITION PETROL INJECTION COOLING SYSTEM EXHAUST RESERVOIR
X90
APRIL 2004 Edition Anglaise
11A
12A
13A
14A
16A
17A
17B
19A
19B
19C
"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed."
All copyrights reserved by Renault. The reproduction or translation in part of whole of the present document, as well as the use of the spare parts reference numbering system, are prohibited without the prior written consent of Renault.
Renault s.a.s. 2004
19D
ENGINE MOUNTING
X90
APRIL 2004
"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed." All copyrights reserved by Renault. The reproduction or translation in part of whole of the present document, as well as the use of the spare parts reference numbering system, are prohibited without the prior written consent of Renault.
Edition Anglaise
Renault s.a.s. 2004
L90 - Section 1 ContentsPage
L90 - Section 1
Contents
10A
ENGINE AND LOWER ENGINE ASSEMBLY Engine identication Oil lter Oil consumption Oil pressure Engine/gearbox assembly Sump Oil pump Multifunction support 10A-1 10A-3 10A-4 10A-5 10A-31 10A-41 10A-43
13A
FUEL SUPPLY Petrol supply circuit Injector rail - Injectors Fuel pressure regulator:Checking Electric fuel: Checking 13A-1 13A-2 13A-6 13A-7
14A
ANTIPOLLUTION Petrol vapour rebreathing: Operation
14A-1 14A-2 14A-3 14A-4
11A
TOP AND FRONT OF ENGINE Accessories belt Timing belt Cylinder head gasket 11A-1 11A-19 11A-29
Fuel vapour rebreathing: Checking Fuel vapour canister Fuel vapour canister:Checking
16A 12A FUEL MIXTURE Specications Air inlet Air lter: Replacement Air lter unit Inlet manifold Exhaust manifold Throttle valve Throttle body: Connection 12A-1 12A-7 12A-9 12A-11 12A-13 12A-19 12A-23 12A-25 17A
STARTING - LOAD Alternator: General information Alternator Starter: Identication Starter motor
16A-1 16A-2 16A-12 16A-13
IGNITION coils Spark plugs 17A-1 17A-5
Contents
17B
PETROL INJECTION Location of components Oxygen sensors Position and speed sensor Fuel supply computer Computer: Connection Special notes Injection warning light Immobiliser function Injection - air conditioning programming Throttle body potentiometer Idle speed correction Richness regulation Central coolant temperature management Special notes on the system (when driving) Conditions for carrying out fault nding (when driving) Combustion misre fault nding Catalytic converter fault nding Oxygen sensor fault nding 17B-1 17B-7 17B-11 17B-13 17B-19 17B-21 17B-23 17B-24 17B-25 17B-26 17B-28 17B-29
19A
COOLING SYSTEM Water pump Thermostat Engine cooling fan assembly 19A-14 19A-18 19A-19
19B
EXHAUST General information Pipe assembly Catalytic converter Expansion chamber Silencer 19B-1 19B-3 19B-5 19B-9 19B-10
19C 17B-30
RESERVOIR Draining the fuel tank 19C-1 19C-3 19C-7 19C-10
17B-31 17B-32 17B-33 17B-34 17B-35 19D
Fuel tank Pump / sender unit / lter Fuel level sensor: Distinctive
ENGINE MOUNTING Suspended engine mounting 19D-1
19A
COOLING SYSTEM General information Specications Checking Diagram Bleeding and lling the cooling circuit. Bleeding the cooling circuit Cooling radiator 19A-1 19A-2 19A-3 19A-4 19A-6 19A-8 19A-9
ENGINE AND LOWER ENGINE ASSEMBLY Oil filter

L90, and K7J, and 710 Essential special tooling Mot. 1329 Oil lter cover - 76 mm diameter
10A
REPLACING THE OIL FILTER
109223
Remove the oil filter using tool (Mot. 1329). Coat the sealing ring of the new oil filter with engine oil. Tighten the oil filter by hand.
10A-1
ENGINE AND LOWER ENGINE ASSEMBLY Oil filter

L90, and K7M, and 710 Essential special tooling Mot. 1329 Oil lter cover - 76 mm diameter
10A
REPLACING THE OIL FILTER
109223
Remove the oil filter using tool (Mot. 1329). Coat the sealing ring of the new oil filter with engine oil. Tighten the oil filter by hand.
10A-2
ENGINE AND LOWER ENGINE ASSEMBLY Oil consumption

L90, and K7J or K7M PROCEDURE FOR MEASURING OIL CONSUMPTION
10A
1 - Filling to the maximum level
Note: The operation should be carried out with the engine warm after the fan assembly has cut in once. Turn the engine off. Wait 2 minutes for all the oil to flow into the oil sump. Carry out a visual inspection using the dipstick. Top up to the "MAX" mark. Make a paint mark on both the filler plug and the sump drain plug in order to be able to check later that it has not been removed.
2 - Customer driving Ask the customer to drive approximately 1240 miles (2000 km) in the vehicle without letting the oil level reach the "MIN" mark.
3 - Topping up
Note: The operation should be carried out with the engine warm after the fan assembly has cut in once. Turn the engine off. Wait 2 minutes for all the oil to flow into the oil sump. Carry out a visual inspection using the dipstick. Top up to the "MAX" mark. Note the quantity of oil added and the mileage covered since the last top-up to maximum level.
4 - Measurement of the oil consumption Oil consumption = Quantity of topping up oil (in litres) / number of kilometres (in thousands).
10A-3
ENGINE AND LOWER ENGINE ASSEMBLY Oil pressure

L90, and K7J or K7M I -CHECKING
10A
Special tooling required Mot. 36-05 Oil pressure gauge kit
Ensure that the engine oil level is between the "MIN" and "MAX" marks.
A B C D E
H
87363
Use the tool (Mot. 836-05) and a long dowel of 22 mm. The oil pressure check must be carried out with the engine warm (approximately 80C). II - USE
K7J engine
K7M engine
C+E+F Connect the pressure gauge in place of the oil pressure switch. III - ENGINE MANAGEMENT K7J/K7M engine: - Idling : 1 bar
- 3000 rpm: 3 bar Torque tighten the oil switch (3.5 daNm).
10A-4
ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

L90, and K7J, and 710 Essential special tooling Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Clip pliers for cooling system hose clips (small model) Remote operation pliers for cooling system hose clips Multiple-adjusting engine mounting support with retaining straps Engine mounting on right-hand side member for operations not requiring removal of the engine Support for removing and retting the engine and gearbox assembly Threaded rods for removing the subframe Essential equipment lling station
10A
10,5 daNm 10.5 daNm 3.7 daNm 10.5 daNm 10.5 daNm
Tightening torques m shock absorber base bolts brake calliper mounting bolts track rod end nuts engine tie-bar mounting bolts wheel bolts
Mot. 1202-02
Mot. 1448
Mot. 1453
REMOVAL
Note: The engine and gearbox assembly can be removed by removing the engine and gearbox/ driveshafts/half-axles/sub-frame assembly. Place the vehicle on a two-post lift. IMPORTANT During this operation, use a strap to secure the vehicle to the lift to prevent it from becoming unbalanced. For the strap tting procedure, (see 02A, Lifting equipment, Underbody lift ).
Mot. 1159-03
Mot. 1390
Tav. 1747
Tightening torques m gearbox rubber mounting mounting bolts gearbox cover mounting nut on the gearbox rubber mounting sub-frame bolts mounting 10.5 daNm 6.2 daNm
10.5 daNm 2.1 daNm 6.2 daNm 10.5 daNm
sub-frame tie-rod upper mounting bolts sub-frame tie-rod lower mounting bolts steering rack mounting bolts
10A-5

L90, and K7J, and 710
10A
3
107846 109184
Disconnect the battery, starting with the negative terminal. Remove: - fuse and relay cover (1), - the fuse holders and relays from their supports (2), - battery mounting clamp (3), - the battery.
107845
10A-6

L90, and K7J, and 710 Drain: - the engine oil if necessary, - the gearbox oil if necessary,
10A
- the cooling circuit via the bottom hose, using tool (Mot. 1202-01), tool (Mot. 1202-02) or tool (Mot. 1448). DIRECTION MANUELLE, and BASIC HEATING
108564
7 5 6
109398
Disconnect fan assembly connector (6). Unclip the electrical harness from fan assembly (7).
108562
Remove: - the injection computer protector in (4), - the injection computer in (5), - the fuse and relay supports, - the electrolyte recovery tray under the battery, - the air suction sleeve on the body, - the front wheels, - the engine undertray, - the bumper mounting bolts under the sub-frame.
10A-7

10A
DIRECTION ASSISTEE, and BASIC HEATING
11 9
107924
Remove the power assisted steering pipe mounting bolts:
- from the top of sub-frame (11) , - on the multifunction support, - on the rear of the cylinder block.
109398
Disconnect: - the low pressure hose on the power assisted steering pump and drain the circuit, - the high-pressure pipe from the power assisted steering pump, - the high-pressure pipe from the steering rack.
Disconnect fan assembly connector (8). Unhook the electrical harness from fan assembly (9).
10
Remove the power assisted steering high-pressure pipe.
109397
Disconnect connector (10) of the power assisted steering pressure switch.
10A-8

10A
DIRECTION MANUELLE, and AIR CONDITIONING
DIRECTION ASSISTEE, and AIR CONDITIONING
12
14
109396
109396
Disconnect fan assembly connectors (12) .
Disconnect connectors (14) of the fan assembly.
15
13
108107
Disconnect connector (13) from the refrigerant pressure sensor. Drain the air conditioning circuit using filling station. Disconnect the air conditioning pipe unions on the air conditioning compressor. WARNING Protective plugs must be inserted into the pipe and air conditioning compressor openings to prevent moisture from getting into the circuit.
109397
10A-9

10A
Drain the air conditioning circuit using the filling station . Disconnect the air conditioning pipe unions on the air conditioning compressor. WARNING Protective plugs must be inserted into the pipe and air conditioning compressor openings to prevent moisture from getting into the circuit.
16
107924
Remove the power assisted steering pipe mounting bolts: - from the top of sub-frame (16) , - on the multifunction support, - on the rear of the cylinder block. Disconnect: - the low pressure hose on the power assisted steering pump and drain the circuit, - the high-pressure pipe from the power assisted steering pump, - the high-pressure pipe from the steering rack. Remove the power assisted steering high-pressure pipe.
19 18
107356
Disconnect: - ball joint (18) of the throttle valve control cable, - cable sleeve stop (19) of the throttle valve control cable.
17
108107
Disconnect connector (17) of the refrigerant pressure sensor.
10A-10

10A
20 22 22
21
22
107357 108565
Disconnect: - the petrol vapour absorber bleeding solenoid valve connector, - the brake servo pipe from the inlet manifold, - petrol vapour rebreather pipe (20) from the inlet manifold. - the fuel supply pipe (21) from the injection rail. IMPORTANT Be careful of petrol splashing out when disconnecting the fuel supply union. Wear gloves during the operation.
Disconnect cooling hoses (22).
23
109493
Remove cooling hoses (23) from their support.
10A-11

10A
24 27 25
26
107934 107935
Remove mounting bolt (24) from the earth strap on the gearbox.
28
99070
Remove: - brake callipers (25) and attach them to the shock absorbers, - track rod ends (26), - bolts (27) from the shock absorber bases, - upper mounting bolts (28) of the sub-frame tie rods, - the two mounting bolts from the steering rack. Attach the steering rack to the body.
10A-12

10A
32
29
30
109494
109214
Remove: - the clutch control cable from clutch fork (29), - the clutch control cable from sleeve stop (30).
Remove mounting bolt (32) from the gear lever fork. Attach the gearbox control linkage to the body.
31
108648
Remove the engine tie-bar. Remove the catalytic converter (see 19B, Exhaust, Catalytic converter).
109213
Remove rubber protection (31) from the gear lever.
10A-13

10A
109495
Fit engine support tool (Mot. 1453) with the retaining belt, by taking the timing end lifting eye as an anchoring point.
35
34
109229
Put a shim under the engine on the right-hand side of the sub-frame: - put a rubber shim under multifunction support (34), - fit tool (Mot. 1159-03) to the rear of engine (35) ,
33
- lower the engine to fix it in place on the right-hand side of the sub-frame.
108649
Remove: - the suspended engine mounting cover mounting bolts,

107930
- the suspended mounting from engine (33) .
Fit engine support tool (Mot. 1453) with the retaining belt, by taking the flywheel end lifting eye as an anchoring point.
10A-14

10A
36
17765
Place tool (Mot. 1390) under the sub-frame.
37
Lower the vehicle down onto the four pads of tool (Mot. 1390).
107929
Remove mounting nut (36) of the gearbox cover on the gearbox rubber mounting. Strike the gearbox mounting stud with a copper hammer to uncouple engine and gearbox assembly from the body. Remove gearbox rubber mounting (37) .
39
108574
Adjust the pad position to ensure the sub-frame is stable on tool (Mot. 1390). Bring the pads into contact with the underside of the sub-frame in (39). Lift the vehicle to separate engine and gearbox/driveshafts/half-axle/sub-frame assembly from the body. WARNING
38
109230
Ensure that no component obstructs the movement of the body around the engine and gearbox assembly.
Put a shim under the gearbox on the left-hand side of the sub-frame: - put a rubber shim under gearbox (38) , - lower the gearbox to fix it in place on the left-hand side of the sub-frame.
10A-15

10A
REFITTING
Torque tighten: - the gearbox rubber mounting mounting bolts (10.5 daNm) , - the gearbox cover mounting nut on the gearbox rubber mounting (6.2 daNm), - the sub-frame mounting bolts (10.5 daNm), - the sub-frame tie-rod upper mounting bolts (2.1 daNm), - the sub-frame tie-rod lower mounting bolts (6.2 daNm), - the steering rack mounting bolts (10.5 daNm)
107927
Use two threaded rods of tool (Tav. 1747) on the sub-frame front mountings to guide the sub-frame when fitting the engine and gearbox assembly.
- the shock absorber base bolts (10,5 daNm) , - the brake calliper mounting bolts (10.5 daNm), - the track rod end nuts (3.7 daNm), - the engine tie-bar mounting bolts (10.5 daNm), - the wheel bolts (10.5 daNm) . Refit the catalytic converter (see 19B, Exhaust, Catalytic converter ). Perform the following operations: - top up the engine oil if necessary, - top up the gearbox oil if necessary,
109495
- fill up and bleed the cooling circuit (see 19A, Cooling, Draining - Filling the cooling circuit).
DIRECTION ASSISTEE, and BASIC HEATING Fill up the power assisted steering circuit. Bleed the power assisted steering circuit by turning the steering wheel fully in one direction then the other with the engine running.
107930
DIRECTION MANUELLE, and AIR CONDITIONING Fill up the air conditioning circuit with filling station.
Use tool (Mot. 1453) to fit the suspended engine mounting of the engine and gearbox assembly. Coat the brake calliper mounting bolts with LOCTITE FRENBLOC.
10A-16

10A
DIRECTION ASSISTEE, and AIR CONDITIONING Fill up the power assisted steering circuit. Bleed the power assisted steering circuit by turning the steering wheel fully in one direction then the other with the engine running. Fill up the air conditioning circuit with filling station.
Proceed in the reverse order to removal. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery: Remove and Ret).
10A-17

L90, and K7M, and 710 Essential special tooling Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Clip pliers for cooling system hose clips (small model) Remote operation pliers for cooling system hose clips Multiple-adjusting engine mounting support with retaining straps Engine mounting on right-hand side member for operations not requiring removal of the engine Support for removing and retting the engine and gearbox assembly Threaded rods for removing the subframe Essential equipment lling station
10A
10.5 daNm 10.5 daNm 3.7 daNm 10.5 daNm 10.5 daNm
Tightening torques m shock absorber base bolts brake calliper mounting bolts track rod end nuts engine tie-bar mounting bolts wheel bolts
Mot. 1202-02
Mot. 1448
Mot. 1453
REMOVAL
Note: The engine and gearbox assembly can be removed by removing the engine and gearbox/ driveshafts/half-axle/sub-frame assembly. Place the vehicle on a two-post lift. IMPORTANT During this operation, secure the vehicle onto the lift with a strap to prevent it from becoming unbalanced. For the strap tting procedure, (see 02A, Lifting equipment, Underbody lift ).
Mot. 1159-03
Mot. 1390
Tav. 1747
Tightening torques m gearbox rubber mounting mounting bolts gearbox cover mounting nut on the gearbox rubber mounting sub-frame bolts mounting 10.5 daNm 6.2 daNm
10.5 daNm 2.1 daNm 6.2 daNm 10.5 daNm
sub-frame tie-rod upper mounting bolts sub-frame tie-rod lower mounting bolts steering rack mounting bolts
10A-18

L90, and K7M, and 710
10A
3
107846 109184
Disconnect the battery, starting with the negative terminal. Remove: - fuse and relay cover (1), - the fuse holders and relays from their supports (2), - battery mounting clamp (3), - the battery.
107845
10A-19

L90, and K7M, and 710 Drain: - the engine oil if necessary, - the gearbox oil if necessary,
10A
- the cooling circuit via the bottom hose, using tool (Mot. 1202-01), tool (Mot. 1202-02) or tool (Mot. 1448). DIRECTION MANUELLE, and BASIC HEATING
108564
109398
Disconnect fan assembly connector (6). Unclip the electrical harness from fan assembly (7).
108562
Remove: - the injection computer protector in (4), - the injection computer in (5), - the fuse and relay supports, - the electrolyte recovery tray under the battery, - the air suction sleeve on the body, - the front wheels, - the engine undertray, - the bumper mounting bolts under the sub-frame.
10A-20

10A
DIRECTION ASSISTEE, and BASIC HEATING
11 9
107924
Remove the power assisted steering pipe mounting bolts:
- from the top of sub-frame (11) , - on the multifunction support, - on the rear of the cylinder block.
109398
Disconnect: - the low pressure hose on the power assisted steering pump and drain the circuit, - the high-pressure pipe from the power assisted steering pump, - the high-pressure pipe from the steering rack.
Disconnect fan assembly connector (8). Unhook the electrical harness from fan assembly (9).
10
Remove the power assisted steering high-pressure pipe.
109397
10A-21

10A
DIRECTION MANUELLE, and AIR CONDITIONING
DIRECTION ASSISTEE, and AIR CONDITIONING
12
14
109396
109396
15
13
108107
Disconnect connector (13) from the refrigerant pressure sensor. Drain the air conditioning circuit using filling station. Disconnect the air conditioning pipe unions on the air conditioning compressor. WARNING Protective plugs must be inserted into the pipe and air conditioning compressor openings to prevent moisture from getting into the circuit.
109397
10A-22

10A
Drain the air conditioning circuit using filling station. Disconnect the air conditioning pipe unions on the air conditioning compressor. WARNING Protective plugs must be inserted into the pipe and air conditioning compressor openings to prevent moisture from getting into the circuit.
16
107924
Remove the power assisted steering pipe mounting bolts: - from the top of sub-frame (16) , - on the multifunction support, - on the rear of the cylinder block. Disconnect: - the low pressure hose on the power assisted steering pump and drain the circuit, - the high-pressure pipe from the power assisted steering pump, - the high-pressure pipe from the steering rack. Remove the power assisted steering high-pressure pipe.
19
18
107356
Disconnect: - ball joint (18) of the throttle valve control cable, - cable sleeve stop (19) of the throttle valve control cable.
17
108107
Disconnect connector (17) of the refrigerant pressure sensor.
10A-23

10A
20 22 21 22
22
107357 108565
Disconnect: - the petrol vapour absorber bleeding solenoid valve connector, - the brake servo pipe from the inlet manifold, - petrol vapour rebreather pipe (20) from the inlet manifold, - fuel supply pipe (21) from the injection rail. IMPORTANT Be careful of petrol splashing out when disconnecting the fuel supply union. Wear gloves during the operation.
Disconnect the cooling hoses (22).
23
109493
Remove cooling hoses (23) from their support.
10A-24

10A
24 27
25
26
107934 107935
Remove mounting bolt (24) from the earth strap on the gearbox.
28
99070
Remove: - brake callipers (25) and attach them to the shock absorbers, - track rod ends (26), - bolts (27) of the shock absorber bases, - upper mounting bolts (28) of the sub-frame tie rods, - the two mounting bolts from the steering rack. Attach the steering rack to the body.
10A-25

10A
32
29
30
109494
109214
Remove: - the clutch control cable from clutch fork (29), - the clutch control cable from sleeve stop (30).
Remove mounting bolt (32) from the gear lever fork. Attach the gearbox control linkage to the body.
31
108648
Remove the engine tie-bar. Remove the catalytic converter (see 19B, Exhaust, Catalytic converter).
109213
Remove rubber protection (31) from the gear lever.
10A-26

10A
109495
Fit engine support tool (Mot. 1453) with the retaining belt, by taking the timing end lifting eye as an anchoring point.
35
34
109229
Put a shim under the engine on the right-hand side of the sub-frame: - put a rubber shim under multifunction support (34), - fit tool (Mot. 1159-03) to the rear of the engine (35),
33
- lower the engine to fix it in place on the right-hand side of the sub-frame.
108649
Remove: - the suspended engine mounting cover mounting bolts,

107930
- the suspended mounting from engine (33) .
Fit engine support tool (Mot. 1453) with the retaining belt, by taking the flywheel end lifting eye as an anchoring point.
10A-27

10A
36
17765
Place tool (Mot. 1390) under the sub-frame.
37
Lower the vehicle onto the four pads of tool (Mot. 1390).
107929
Remove mounting nut (36) of the gearbox cover on the gearbox rubber mounting. Strike the gearbox mounting stud with a copper hammer to uncouple the engine and gearbox assembly from the body. Remove gearbox rubber mounting (37) .
39
108574
Adjust the pad position to ensure the sub-frame is stable on tool (Mot. 1390). Bring the pads into contact with the underside of the sub-frame in (39). Lift the vehicle to separate the engine and gearbox/driveshafts/half-axle/sub-frame assembly from the body. WARNING Ensure that no component obstructs the movement of the body around the engine and gearbox assembly.
109230
38
Put a shim under the gearbox on the left-hand side of the sub-frame: - put a rubber shim under gearbox (38) , - lower the gearbox to fix it in place on the left-hand side of the sub-frame.
10A-28

10A
REFITTING
Torque tighten: - the gearbox rubber mounting mounting bolts (10.5 daNm) , - the gearbox cover mounting nut on the gearbox rubber mounting (6.2 daNm), - the sub-frame mounting bolts (10.5 daNm), - the sub-frame tie-rod upper mounting bolts (2.1 daNm), - the sub-frame tie-rod lower mounting bolts (6.2 daNm), - the steering rack mounting bolts (10.5 daNm)
107927
Use two threaded rods of tool (Tav. 1747) on the sub-frame front mountings to guide the sub-frame when fitting the engine and gearbox assembly.
- the shock absorber base bolts (10.5 daNm) , - the brake calliper mounting bolts (10.5 daNm), - the track rod end nuts (3.7 daNm), - the engine tie-bar mounting bolts (10.5 daNm), - the wheel bolts (10.5 daNm) . Refit the catalytic converter (see 19B, Exhaust, Catalytic converter ). Perform the following operations: - top up the engine oil if necessary, - top up the gearbox oil if necessary,
109495
- fill up and bleed the cooling circuit (see 19A, Cooling, Draining - Filling the cooling circuit).
DIRECTION ASSISTEE, and BASIC HEATING Fill up the power assisted steering circuit. Bleed the power assisted steering circuit by turning the steering wheel fully in one direction then the other with the engine running.
107930
DIRECTION MANUELLE, and AIR CONDITIONING Fill up the air conditioning circuit with filling station.
Use tool (Mot. 1453) to fit the suspended engine mounting of the engine and gearbox assembly. Coat the brake calliper mounting bolts with LOCTITE FRENBLOC.
10A-29

10A
DIRECTION ASSISTEE, and AIR CONDITIONING Fill up the power assisted steering circuit. Bleed the power assisted steering circuit by turning the steering wheel fully in one direction then the other with the engine running. Fill up the air conditioning circuit with filling station.
Proceed in the reverse order to removal. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery: Remove and Ret).
10A-30
ENGINE AND LOWER ENGINE ASSEMBLY Sump

L90, and K7J, and 710 Essential special tooling Tav. 1747 Threaded rods for removing the subframe
10A
Tightening torques m sump mounting bolts engine to gearbox coupling bolts sub-frame bolts mounting 1.4 daNm 4.4 daNm
(10.5 daNm) Remove: 10.5 daNm 2.1 daNm 6.2 daNm 10.5 daNm 10.5 daNm
108648
steering rack mounting bolts sub-frame tie-rod upper mounting bolts sub-frame tie-rod lower mounting bolts engine tie-bar mounting bolts wheel bolts
- the engine tie-bar, - the front wheels, - the lower ball joints, - the catalytic converter (see 19B, Exhaust, Catalytic converter), - the two mounting bolts from the steering rack. Attach the steering rack to the body. DIRECTION ASSISTEE
REMOVAL
Place the vehicle on a two-post lift. Remove: - the engine undertray, - the bumper mounting bolts under the sub-frame.
Drain the engine oil.
1
107924
Remove mounting bolt (1) of the power assisted steering pipe on the top of the sub-frame.
10A-31

10A
107934
108645
Remove mounting bolt (2) of the sub-frame tie-rods.
3 3
107924
Remove sub-frame mounting bolts (3) one at a time, then replace them by the threaded rods of tool (Tav. 1747).
108644
IMPORTANT Make sure the threaded rod of tool (Tav . 1747) is sufciently screwed into the threaded hole and that the nut of the tool is properly resting on the sub-frame.
Lower the sub-frame by at least 120 mm by progressively unscrewing the nuts of tool (Tav. 1747).
10A-32

10A
107936
Remove: - coupling bolts (4) of the engine and gearbox, - the sump mounting bolts, - the sump.
REFITTING
WARNING Replace: - the sump gasket, - the sub-frame mounting bolts.
10A-33

10A
Note:
Excess sealant could be squeezed out when the parts are tightened. The sealing compound/uid mixture can cause damage to certain components (engine, radiator, etc.).
20166
5
20167
Apply: - four beads (5) of RHODORSEAL 56615 mm in diameter, - two spots (6) of RHODORSEAL 5661 of a diameter of 7 mm at the intersection of the crankshaft closing panel and the cylinder block.
Note: The gasket faces must be clean, dry and free from grease (avoid nger marks).
10A-34

10A
- the steering rack mounting bolts (10.5 daNm), - the sub-frame tie-rod upper mounting bolts (2.1 daNm), - the sub-frame tie-rod lower mounting bolts (6.2 daNm), - the engine tie-bar mounting bolts (10.5 daNm), - the wheel bolts (10.5 daNm) . Refit the catalytic converter (see 19B, Exhaust, Catalytic converter ). Proceed in the reverse order to removal. Top up the engine oil.
107936
12 16 20
1 13 17
19 18 3 2 6 10 14
107792
Pretighten to torque and in order: - the sump mounting bolts (0.8 daNm), - the engine to gearbox coupling bolts (0.8 daNm). Torque tighten in order: - the sump mounting bolts (1.4 daNm), - the engine to gearbox coupling bolts (4.4 daNm). Torque tighten: - the sub-frame mounting bolts ((10.5 daNm)),
10A-35

L90, and K7M, and 710 Essential special tooling Tav. 1747 Threaded rods for removing the subframe
10A
Tightening torques m sump mounting bolts engine to gearbox coupling bolts sub-frame bolts mounting 1.4 daNm 4.4 daNm
(10.5 daNm) Remove: 10.5 daNm 2.1 daNm 6.2 daNm 10.5 daNm 10.5 daNm
108648
steering rack mounting bolts sub-frame tie-rod upper mounting bolts sub-frame tie-rod lower mounting bolts engine tie-bar mounting bolts wheel bolts
- the engine tie-bar, - the front wheels, - the lower ball joints, - the catalytic converter (see 19B, Exhaust, Catalytic converter), - the two mounting bolts from the steering rack. Attach the steering rack to the body.
REMOVAL
Place the vehicle on a two-post lift. Remove: - the engine undertray, - the bumper mounting bolts under the sub-frame.
Drain the engine oil.
107934
Remove mounting bolt (2) of the sub-frame tie-rods.
10A-36

10A
107924
Remove sub-frame mounting bolts (3) one at a time, then replace them by one of the threaded rods of tool (Tav. 1747). IMPORTANT Make sure the threaded rod of tool (Tav . 1747) is sufciently screwed into the threaded hole and that the nut of the tool is properly resting on the sub-frame.
108645
108644
Lower the sub-frame by at least 120 mm by progressively unscrewing the nuts of tool (Tav. 1747).
10A-37

10A
107936
Remove: - the coupling bolts (4) of the engine and gearbox, - the sump mounting bolts, - the sump.
REFITTING
WARNING Replace: - the sump gasket, - the sub-frame mounting bolts.
10A-38

10A
Note:
Excess sealant could be squeezed out when the parts are tightened. The sealing compound/uid mixture can cause damage to certain components (engine, radiator, etc.).
5
20166
5
20167
Apply: - four beads (5) of RHODORSEAL 56615 mm in diameter, - two spots (6) of RHODORSEAL 5661 of a diameter of 7 mm at the intersection of the crankshaft closing panel and the cylinder block.
Note: The gasket faces must be clean, dry and free from grease (avoid nger marks).
10A-39

10A
- the steering rack mounting bolts (10.5 daNm), - the sub-frame tie-rod upper mounting bolts (2.1 daNm), - the sub-frame tie-rod lower mounting bolts (6.2 daNm), - the engine tie-bar mounting bolts (10.5 daNm), - the wheel bolts (10.5 daNm) . Refit the catalytic converter (see 19B, Exhaust, Catalytic converter ). Proceed in the reverse order to removal. Top up the engine oil.
107936
12 16 20
4 1 5 9 13 17
19 18 15 11 7 3 2 6 10 14
107792
Pretighten to torque and in order: - the sump mounting bolts (0.8 daNm), - the engine to gearbox coupling bolts (0.8 daNm). Torque tighten in order: - the sump mounting bolts (1.4 daNm), - the engine to gearbox coupling bolts (4.4 daNm). Torque tighten: - the sub-frame mounting bolts ((10.5 daNm)),
10A-40
ENGINE AND LOWER ENGINE ASSEMBLY Oil pump

10A
Tightening torques m oil pump mounting bolts 2.5 daNm
REMOVAL
Place the vehicle on a two-post lift. Remove the sump (see 10A, Engine and peripherals, Sump).
108646
Remove: - the mounting (1) bolts of the oil pump, - the oil pump.
REFITTING
Tighten to torque the oil pump mounting bolts (2.5 daNm). Refit the sump (see 10A, Engine and peripherals, Sump).
10A-41
ENGINE AND LOWER ENGINE ASSEMBLY Oil pump

10A
Tightening torques m oil pump mounting bolts 2.5 daNm
REMOVAL
Place the vehicle on a two-post lift. Remove the sump (see 10A, Engine and peripherals, Sump).
108646
Remove: - the mounting (1)bolts of the oil pump, - the oil pump.
REFITTING
Tighten to torque the oil pump mounting bolts (2.5 daNm). Refit the sump (see 10A, Engine and peripherals, Sump).
10A-42
ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support

L90, and K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING
10A
Tightening torques m multifunction support mounting bolts power assisted steering pump mounting bolts 4.4 daNm 2.1 daNm
- the power assisted steering pump mounting bolts (2.1 daNm). Refit the alternator (see 16A, Starting - Charge, Alternator). Proceed in the reverse order to removal.
REMOVAL
Mount the vehicle on a two-post lift. Remove: - the engine undertray, - the alternator (see 16A, Starting - Charge, Alternator). Remove the power assisted steering pump mounting bolts. Attach the power assisted steering pump to the subframe.
1 1
109226
Remove: - the mounting (1) bolts of the multifunction support, - the multifunction support.
REFITTING
Position the multifunction support. Torque tighten: - the multifunction support mounting bolts (4.4 daNm),
10A-43

L90, and K7J, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING
10A
Tightening torques m multifunction support mounting bolts air conditioning compressor mounting bolts 4.4 daNm 2.1 daNm
REMOVAL
Place the vehicle on a two-post lift. Remove the engine undertray.
1
109228
REFITTING
Position the multifunction support. Torque tighten:
2
109227
- the multifunction support mounting bolts (4.4 daNm), - the air conditioning compressor mounting bolts (2.1 daNm). Refit the air conditioning compressor belt (see 11A, Top and front of engine, Accessories belt ). Proceed in the reverse order to removal.
Disconnect the connector (1) of the air conditioning compressor. Remove: - the air conditioning compressor belt (see 11A, Top and front of engine, Accessories belt ), - the three mounting (2) bolts of the air conditioning compressor. Attach the air conditioning compressor to the subframe.
10A-44

L90, and K7J, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING
10A
Tightening torques m M10 mounting bolts of the multifunction support M8 mounting bolts of the multifunction support 4.4 daNm
2 1
2.1 daNm
REMOVAL
Place the vehicle on a two-post lift. Remove: - the engine undertray, - the alternator (see 16A, Starting - Charge, Alternator).
109224
109221
Remove: - the mounting bolts (1) and (2) of the multifunction support, - the multifunction support.
REFITTING
Position the multifunction support. Torque tighten: - the M10 mounting bolts of the multifunction support (4.4 daNm)(1),
10A-45

L90, and K7J, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING - the M8 mounting bolts of the multifunction support (2.1 daNm)(2). Refit the alternator (see 16A, Starting - Charge, Alternator). Proceed in the reverse order to removal.
10A
10A-46

L90, and K7M, and 710, and DIRECTION ASSISTEE, and BASIC HEATING
10A
Tightening torques m multifunction support mounting bolts power assisted steering pump mounting bolts 4.4 daNm 2.1 daNm
- the power assisted steering pump mounting bolts (2.1 daNm). Refit the alternator (see 16A, Starting - Charge, Alternator). Proceed in the reverse order to removal.
REMOVAL
Place the vehicle on a two-post lift. Remove: - the engine undertray, - the alternator (see 16A, Starting - Charge, Alternator). Remove the power assisted steering pump mounting bolts. Attach the power assisted steering pump to the subframe.
1 1
109226
REFITTING
Position the multifunction support. Torque tighten: - the multifunction support mounting bolts (4.4 daNm),
10A-47

L90, and K7M, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING
10A
Tightening torques m multifunction support mounting bolts air conditioning compressor mounting bolts 4.4 daNm 2.1 daNm
REMOVAL
Place the vehicle on a two-post lift. Remove the engine undertray.
1
109228
REFITTING
Position the multifunction support. Torque tighten:
- the multifunction support mounting bolts (4.4 daNm),

109227
- the air conditioning compressor mounting bolts (2.1 daNm). Refit the air conditioning compressor belt (see 11A, Top and front of engine, Accessories belt ). Proceed in the reverse order to removal.
Disconnect the connector (1) of the air conditioning compressor. Remove: - the air conditioning compressor belt (see 11A, Top and front of engine, Accessories belt ), - the mounting (2) bolts of the air conditioning compressor. Attach the air conditioning compressor to the subframe.
10A-48

L90, and K7M, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING
10A
Tightening torques m M10 mounting bolts of the multifunction support M8 mounting bolts of the multifunction support 4.4 daNm
2.1 daNm
1 1
REMOVAL
Place the vehicle on a two-post lift. Remove the engine undertray. Remove the alternator (see 16A, Starting - Charge, Alternator).
109224
109221
Remove: - the mounting bolts (1) and (2) of the multifunction support, - the multifunction support.
REFITTING
Position the multifunction support. Torque tighten: - the five M10 mounting bolts of the multifunction support (4.4 daNm)(1) ,
10A-49

L90, and K7M, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING - the two M8 mounting bolts of the multifunction support (2.1 daNm)(2). Refit the alternator (see 16A, Starting - Charge, Alternator). Proceed in the reverse order to removal.
10A
10A-50
TOP AND FRONT OF ENGINE Accessories belt

L90, and K7J, and 710, and DIRECTION MANUELLE, and BASIC HEATING Essential special tooling Mot. 1505 Mot. 1715 Belt tension setting tool (frequency meter) Belt tension setting tool (frequency meter)
11A
Tightening torques m alternator mounting bolt alternator mounting bolt wheel bolts 2.1 daNm 4.4 daNm 10.5 daNm
REMOVAL
2
WARNING Never run the engine against its operating direction. Mount the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove the front right-hand wheel.
109237
Slacken: - the alternator mounting screw (1), - the alternator mounting bolt (2). Remove the accessories belt.
REFITTING
WARNING Replace any belt that has been removed.
11A-1

L90, and K7J, and 710, and DIRECTION MANUELLE, and BASIC HEATING
11A
16300
( 3) ( 4) ( 5)
Crankshaft Alternator Measuring point
Refit the accessories belt. Tension the belt by turning the alternator. Set the belt tension using tool (Mot. 1505) or (Mot. 1715) to a value of 305 Hz 10, (see Technical Note 3786A, Engine and peripherals, 10A, Belt tension tester: Use). Turn the engine through three revolutions to position the belt correctly. Check the belt tension using tool (Mot. 1505) or (Mot. 1715). If the belt tension is outside tolerance, readjust it. Torque tighten: - the alternator mounting bolt (2.1 daNm), - the alternator mounting bolt (4.4 daNm). Proceed in the reverse order to removal. Torque tighten the wheel bolts (10.5 daNm).
WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery: Remove and Ret).
11A-2

L90, and K7M, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING Essential special tooling Mot. 1505 Mot. 1715 Belt tension setting tool (frequency meter) Belt tension setting tool (frequency meter)
11A
II - REMOVING THE ALTERNATOR BELT
Tightening torques m alternator screw mounting 2.1 daNm
alternator mounting bolt wheel bolts
4.4 daNm 10.5 daNm
REMOVAL
WARNING Never run the engine against its operating direction. Mount the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove the front right wheel. I -REMOVING THE AIR CONDITIONING COMPRESSOR BOLT
109236
Slacken: - the alternator mounting screw (1), - the alternator mounting bolt (2). Remove the alternator belt.
REFITTING
WARNING Replace any belt that has been removed. I -REFITTING THE ALTERNATOR BELT Refit the alternator belt.
109636
Cut the air conditioning compressor belt using cutting pliers.
11A-3

11A
II - REFITTING THE AIR CONDITIONING COMPRESSOR BELT
Note:
The air conditioning compressor belt does not have a tension wheel, as it is tensioned automatically, and it is retted using a tool supplied with the belt.
16300
( 3) ( 4) ( 5)
Crankshaft Alternator
6
109635
Measuring point
Air conditioning compressor belt fitting tool (6).
Tension the belt by turning the alternator. Set the belt tension using tool (Mot. 1505) or (Mot. 1715) to a value of 305 10 Hz, (see Technical Note 3786A, Engine and peripherals, 10A, Belt tension tester: Use). Turn the engine through three revolutions to position the belt correctly. Check the belt tension using tool (Mot. 1505) or (Mot. 1715). If the belt tension is outside tolerance, readjust it. Torque tighten: - the alternator mounting screw (2.1 daNm), - the alternator mounting bolt (4.4 daNm).
109637
Clip the belt fitting tool on the crankshaft pulley as shown in the diagram.
11A-4

11A
109638
109640
Mount the belt and slide round the belt fitting tool by hand clockwise by approximately 90.
Rotate the crankshaft clockwise until the belt is in place on the crankshaft pulley.
Note: The air conditioning compressor belt tting tool is single-use, and must be discarded after use.
109639
Position hook (7) as shown in the diagram, with the longest end of the hook behind the multifunction support.
109641
Turn the crankshaft through two revolutions to correctly position the air conditioning compressor belt.
Torque tighten the wheel bolts (10.5 daNm).
11A-5

11A
REFITTING
Tightening torques m tension wheel mounting bolt pulley mounting bolt wheel bolts 2.1 daNm 2.1 daNm 10.5 daNm WARNING When replacing the belt, be sure to replace the tension wheels and idler pulleys. Torque tighten: - the tension wheel mounting bolt (2.1 daNm), WARNING Never run the engine against its operating direction. Mount the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove the front right-hand wheel. - the pulley mounting bolt (2.1 daNm). WARNING Replace any belt that has been removed.
REMOVAL
5 8 3 4 7
105998
(3)
Crankshaft Air conditioning compressor Alternator Power assisted steering pump Idler pulley Tension wheel
1 2
14494-3
(4) (5) (6) (7) (8)
Turn the tension wheel clockwise, using a wrench (1), to loosen the belt. Lock the tension wheel using a 6 mm Allen key (2). Remove the accessories belt.
11A-6

11A
106001
109238
Refit the accessories belt. WARNING Make sure that the inner tooth on all the pulleys remains free.
Remove the 6 mm Allen key. Turn the engine through three revolutions to position the belt correctly. Proceed in the reverse order to removal. Torque tighten the wheel bolts (10.5 daNm). WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery: Remove and Ret).
11A-7

L90, and K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING Essential special tooling Mot. 1505 Mot. 1715 Belt tension setting tool (frequency meter) Belt tension setting tool (frequency meter)
11A
REFITTING
WARNING Tightening torques m tension wheel mounting bolts wheel bolts 2.1 daNm The tension wheel must be replaced when the belt is replaced.
10.5 daNm
REMOVAL
2
WARNING Never run the engine against its operating direction.
5 4
6
Mount the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove the front right-hand wheel.
106045
(2) (3) (4) (5) (6)
Crankshaft Alternator Power assisted steering pump Tension wheel Measuring point
109235
Slacken the tension wheel mounting bolts (1). Remove the accessories belt.
11A-8

11A
7
105999
109235
Refit the accessories belt. WARNING Make sure that the outer tooth on all the pulleys remains free.
Insert a long bolt (7) on the multifunction support. Tension the belt using the bolt (7). Set the belt tension using tool (Mot. 1505) or (Mot. 1715) to a value of 204 5 Hz, (see Technical Note 3786A, Engine and peripherals, 10A, Belt tension tester: Use ). Turn the engine through three revolutions to position the belt correctly. Check the belt tension using tool (Mot. 1505) or (Mot. 1715). If the belt tension is outside tolerance, readjust it. Remove the bolt (7). Torque tighten the tension wheel mounting bolts (2.1 daNm). Proceed in the reverse order to removal. Torque tighten the wheel bolts (10.5 daNm). WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery: Remove and Ret).
11A-9

L90, and K7J, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING Essential special tooling Mot. 1505 Mot. 1715 Belt tension setting tool (frequency meter) Belt tension setting tool (frequency meter)
11A
II - REMOVING THE ALTERNATOR BELT
Tightening torques m alternator screw mounting 2.1 daNm
alternator mounting bolt wheel bolts
4.4 daNm 10.5 daNm
REMOVAL
WARNING Never run the engine against its operating direction. Mount the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove the front right-hand wheel. I -REMOVING THE AIR CONDITIONING COMPRESSOR BELT
109236
Slacken: - the alternator mounting screw (1), - the alternator mounting bolt (2). Remove the alternator belt.
REFITTING
WARNING Replace any belt that has been removed. I -REFITTING THE ALTERNATOR BELT Refit the alternator belt.
109636
Cut the air conditioning compressor belt using cutting pliers.
11A-10

11A
II - REFITTING THE AIR CONDITIONING COMPRESSOR BELT
Note:
The air conditioning compressor belt does not have a tension wheel, as it is tensioned automatically, and it is retted using a tool supplied with the belt.
16300
( 3) ( 4) ( 5)
Crankshaft Alternator
6
109635
Measuring point
Air conditioning compressor belt fitting tool (6).
Tension the belt by turning the alternator. Set the belt tension using tool (Mot. 1505) or (Mot. 1715) to a value of 305 Hz 10, (see Technical Note 3786A, Engine and peripherals, 10A, Belt tension tester: Use). Turn the engine through three revolutions to position the belt correctly. Check the belt tension using tool (Mot. 1505) or (Mot. 1715). If the belt tension is outside tolerance, readjust it. Torque tighten: - the alternator mounting screw (2.1 daNm), - the alternator mounting bolt (4.4 daNm).
109637
Clip the belt fitting tool on the crankshaft pulley as shown in the diagram.
11A-11

11A
109638
109640
Mount the belt and slide round the belt fitting tool by hand clockwise by approximately 90.
Rotate the crankshaft clockwise until the belt is in place on the crankshaft pulley.
Note: The air conditioning compressor belt tting tool is single-use, and must be discarded after being used.
109639
Position the hook (7) as shown in the diagram, with the longest end of the hook behind the multifunction support.
109641
Turn the crankshaft through two revolutions to correctly position the air conditioning compressor belt.
Torque tighten the wheel bolts (10.5 daNm).
11A-12

L90, and K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING Essential special tooling Mot. 1505 Mot. 1715 Belt tension setting tool (frequency meter) Belt tension setting tool (frequency meter)
11A
REFITTING
WARNING Tightening torques m tension wheel mounting bolts wheel bolts 2.1 daNm The tension wheel must be replaced when the belt is replaced.
10.5 daNm
REMOVAL
2
WARNING Never run the engine against its operating direction.
5 4
6
Mount the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove the front right-hand wheel.
106045
(2) (3) (4) (5) (6)
Crankshaft Alternator Power assisted steering pump Tension wheel Measuring point
109235
Slacken the tension wheel mounting bolts (1). Remove the accessories belt.
11A-13

11A
7
105999
109235
Refit the accessories belt. WARNING Make sure that the outer tooth on all the pulleys remains free.
Insert a long bolt (7) into the multifunction support. Tension the belt using bolt (7). Set the belt tension using tool (Mot. 1505) or (Mot. 1715) to a value of 204 5 Hz, (see Technical Note 3786A, Engine and peripherals, 10A, Belt tension tester: Use ). Turn the engine through three revolutions to position the belt correctly. Check the belt tension using tool (Mot. 1505) or (Mot. 1715). If the belt tension is outside tolerance, readjust it. Remove the bolt (7). Torque tighten the tension wheel mounting bolts (2.1 daNm). Proceed in the reverse order to removal. Torque tighten the wheel bolts (10.5 daNm). WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery: Remove and Ret).
11A-14

11A
REFITTING
Tightening torques m tension wheel mounting bolt idler pulley mounting bolt wheel bolts 2.1 daNm 2.1 daNm WARNING 10.5 daNm When replacing the belt, be sure to replace the tension wheels and idler pulleys. Torque tighten: - the tension wheel mounting bolt (2.1 daNm), WARNING Never run the engine against its operating direction. Mount the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove the front right-hand wheel. - the idler pulley mounting bolt (2.1 daNm). WARNING Replace any belt that has been removed.
REMOVAL
5 8 3 4 7
105998
(3) (4)
Crankshaft Air conditioning compressor Alternator Power assisted steering pump Idler pulley Tension wheel
(5)
2
14494-3
(6) (7) (8)
Turn the tension wheel clockwise, using a wrench (1), to relax the belt. Lock the tension wheel using a 6 mm Allen key (2). Remove the accessories belt.
11A-15

11A
106001
109238
Refit the accessories belt. WARNING Make sure that the inner tooth on all the pulleys remains free.
Remove the 6 mm Allen key. Turn the engine through three revolutions to position the belt correctly. Proceed in the reverse order to removal. Torque tighten the wheel bolts (10.5 daNm). WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery: Remove and Ret).
11A-16

L90, and K7M, and 710, and DIRECTION MANUELLE, and BASIC HEATING Essential special tooling Mot. 1505 Mot. 1715 Belt tension setting tool (frequency meter) Belt tension setting tool (frequency meter)
11A
Tightening torques m alternator mounting bolt alternator mounting bolt wheel bolts 2.1 daNm 4.4 daNm 10.5 daNm
REMOVAL
WARNING Never run the engine against its operating direction. Mount the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove the front right wheel.
2
109237
Slacken: - the alternator mounting screw (1), - the alternator mounting bolt (2). Remove the accessories belt.
REFITTING
11A-17

L90, and K7M, and 710, and DIRECTION MANUELLE, and BASIC HEATING
11A
3 5
16300
( 3) ( 4) ( 5)
Crankshaft Alternator Measuring point
Refit the accessories belt. Tension the belt by turning the alternator. Set the belt tension using tool (Mot. 1505) or (Mot. 1715) to a value of 305 Hz 10, (see Technical Note 3786A, Engine and peripherals, 10A, Belt tension tester: Use). Turn the engine through three revolutions to position the belt correctly. Check the belt tension using tool (Mot. 1505) or (Mot. 1715). If the belt tension is outside tolerance, readjust it. Torque tighten: - the alternator mounting bolt (2.1 daNm), - the alternator mounting bolt (4.4 daNm). Proceed in the reverse order to removal. Torque tighten the wheel bolts (10.5 daNm).
11A-18
TOP AND FRONT OF ENGINE Timing belt

L90, and K7J, and 710 Essential special tooling Mot. 1453 Multiple-adjusting engine mounting support with retaining straps Top dead centre locating pin Timing belt prestressing tool Timing gear belt tensioner tool Belt tension setting tool (frequency meter) Belt tension setting tool (frequency meter) Essential equipment low torque wrench Remove: - the engine undertray,
11A
- the accessories belt (see 11A, Top and front of engine, Accessories belt ). - the crankshaft accessories pulley by locking the flywheel using a screwdriver.
Mot. 1489 Mot. 1501 Mot. 1135-01
Mot. 1505 Mot. 1715
109495
Fit engine support tool (Mot. 1453) with the retaining belt, by taking the timing end lifting eye as an anchoring point. 5 daNm 3 daNm + 80 5 4.4 daNm
Tightening torques m the tension wheel mounting nut crankshaft pulley mounting bolt M10 mounting bolts of the upper timing cover M8 mounting bolts of the upper timing cover lower timing mounting bolts cover
1
2.2 daNm 0.8 daNm 6.2 daNm
suspended engine mounting cover mounting bolts
WARNING Never turn the engine against its operating direction. Remove suspended engine mounting (1).
108649
REMOVAL
Place the vehicle on a two-post lift.
11A-19

11A
2
107359 107498
Remove TDC pin plug (2).
107499
Remove: - lower timing cover (3), - upper timing cover (4).
11A-20

L90, and K7J, and 710 ADJUSTING THE TIMING
11A
6
107494 107497
Remove: - tension wheel mounting nut (7), - the timing belt, - the tension wheel.
Rescrew the crankshaft accessories pulley bolt with a spacer. Turn the crankshaft clockwise to bring the camshaft sprocket one tooth before the vertical axle of the sprocket (top point (5)) and the crankshaft sprocket mark one tooth before the vertical axle of the sprocket (low point (6)). Insert TDC setting rod (Mot. 1489). Turn the crankshaft clockwise by pushing on TDC setting rod (Mot. 1489) until the crankshaft times.
REFITTING
WARNING The tension wheel must be replaced when the belt is replaced.
WARNING It is essential to replace the crankshaft accessories pulley mounting bolt. Refit the tension wheel.
11A-21

11A
10
9
107494 107493
Fit the timing belt by aligning the belt markings with those of the sprockets of camshaft (8) and crankshaft (9). Rolling order: - crankshaft pulley, - tension wheel, - camshaft pulley, - water pump pulley. PROCEDURE FOR TENSIONING TIMING BELT Make the tension wheel push onto the timing belt. Lightly tighten the tension wheel mounting nut. Remove TDC setting rod (Mot. 1489).
11
16293
Fit timing belt pretensioning torque tool (Mot. 1501) on camshaft sprocket (10). Apply pretensioning torque to the timing belt section (11), with a low torque wrench adjusted to torque 1 daNm. Remove the tool (Mot. 1501).
11A-22

11A
13
Angle tighten to torque the crankshaft pulley mounting bolt (3 daNm + 80 5), by blocking the flywheel with a screwdriver.
12
14
107492
Fit the auxiliary timing belt tensioner tool (Mot. 113501)(12) . Tighten the timing belt, by pivoting the tension wheel with tool (Mot. 1135-01) anti-clockwise. Adjust the belt tension with tool (Mot. 1505) or (Mot. 1715) to the value 165 Hz 10, (see Technical Note 3786A, Engine and peripherals, 10A, Belt tension tester: Use). Tighten to torque the tension wheel mounting nut (5 daNm). Rotate the crankshaft clockwise through two revolutions. Set the engine at Top Dead Centre using tool (Mot. 1489). Remove the TDC setting rod (Mot. 1489). Refit the timing belt pretensioning torque tool (Mot. 1501) on the camshaft sprocket Apply pretensioning torque to the timing belt section, with a low torque wrench adjusted to torque 1 daNm Remove the tool (Mot. 1501). Check using tool (Mot. 1505) or (Mot. 1715), that the timing belt tension is 165 Hz 10. If the tension value is outside tolerances, adjust it by starting the tensioning process from the beginning.
107499
Coat the upper timing cover mounting bolts with LOCTITE FRENETANCH . Torque tighten: - the M10 mounting bolts of the upper timing cover (4.4 daNm)(13) , - the M8 mounting bolts of the upper timing cover (2.2 daNm)(14), - the lower timing cover mounting bolts (0.8 daNm), - the suspended engine mounting cover mounting bolts (6.2 daNm). Refit the accessories belt (see 11A, Top and front of engine, accessories belt).
11A-23

L90, and K7M, and 710 Essential special tooling Mot. 1453 Multiple-adjusting engine mounting support with retaining straps Top dead centre locating pin Timing belt prestressing tool Timing gear belt tensioner tool Belt tension setting tool (frequency meter) Belt tension setting tool (frequency meter) Essential equipment low torque wrench Remove: - the engine undertray,
11A
- the accessories belt (see 11A, Top and front of engine, Accessories belt ). - the crankshaft accessories pulley by locking the flywheel using a screwdriver.
Mot. 1489 Mot. 1501 Mot. 1135-01
Mot. 1505 Mot. 1715
109495
Fit the engine support tool (Mot. 1453) with the retaining belt, by taking the timing end lifting eye as an anchoring point. 5 daNm 3 daNm + 80 5 4.4 daNm
Tightening torques m the tension wheel mounting nut crankshaft pulley mounting bolt M10 mounting bolts of the upper timing cover M8 mounting bolts of the upper timing cover lower timing mounting bolts cover
1
2.2 daNm 0.8 daNm 6.2 daNm
suspended engine mounting cover mounting bolts
WARNING Never turn the engine against its operating direction. Remove the suspended engine mounting (1).
108649
REMOVAL
Place the vehicle on a two-post lift.
11A-24

11A
2
107359 107498
Remove the TDC pin plug (2).
107499
Remove: - the lower timing cover (3), - the upper timing cover (4).
11A-25

L90, and K7M, and 710 ADJUSTING THE TIMING
11A
6
107494 107497
Remove: - tension wheel mounting nut (7), - the timing belt, - the tension wheel.
Rescrew the crankshaft accessories pulley bolt with a spacer. Turn the crankshaft clockwise to bring the camshaft sprocket one tooth before the vertical axle of the sprocket (top point (5)) and the crankshaft sprocket mark one tooth before the vertical axle of the sprocket (low point (6)). Insert TDC setting rod (Mot. 1489). Turn the crankshaft clockwise by pushing on TDC setting rod (Mot. 1489) until the crankshaft times.
REFITTING
WARNING The tension wheel must be replaced when the belt is replaced.
WARNING It is essential to replace the crankshaft accessories pulley mounting bolt. Refit the tension wheel.
11A-26

11A
10
9
107494 107493
Fit the timing belt by aligning the belt markings with those of the camshaft sprockets (8) and crankshaft sprockets (9). Rolling order: - crankshaft pulley, - tension wheel, - camshaft pulley, - water pump pulley. PROCEDURE FOR TENSIONING TIMING BELT Make the tension wheel push onto the timing belt. Lightly tighten the tension wheel mounting nut. Remove TDC setting rod (Mot. 1489).
11
16293
Fit timing belt pretensioning torque tool (Mot. 1501) on camshaft sprocket.(10). Apply pretensioning torque to the timing belt section (11), with a low torque wrench adjusted to torque 1 daNm. Remove tool (Mot. 1501).
11A-27

11A
Angle tighten to torque the crankshaft pulley mounting bolt (3 daNm + 80 5), by blocking the flywheel with a screwdriver.
13 12
14
107492
Fit timing auxiliary belt tensioner tool (Mot. 113501)(12) . Tighten the timing belt, by pivoting the tension wheel with tool (Mot. 1135-01) anti-clockwise. Adjust the belt tension with tool (Mot. 1505) or (Mot. 1715) to the value 165 Hz 20, (see Technical Note 3786A, Engine and peripherals, 10A, Belt tension tester: Use). Tighten to torque the tension wheel mounting nut (5 daNm). Rotate the crankshaft clockwise through two revolutions. Set the engine at Top Dead Centre using tool (Mot. 1489). Remove TDC setting rod (Mot. 1489). Refit timing belt pretensioning torque tool (Mot. 1501) on the camshaft sprocket Apply pretensioning torque to the timing belt section, with a low torque wrench adjusted to torque 1 daNm Remove tool (Mot. 1501). Check using tool (Mot. 1715) or (Mot. 1489) that the timing belt tension is 165 Hz 20. If the tension value is outside tolerances, adjust it by starting the tensioning process from the beginning.
107499
Coat the upper timing cover mounting bolts with LOCTITE FRENETANCH . Torque tighten: - the M10 mounting bolts of the upper timing cover (4.4 daNm)(13) , - the M8 mounting bolts of the upper timing cover (2.2 daNm)(14), - the lower timing cover mounting bolts (0.8 daNm), - the suspended engine mounting cover mounting bolts (6.2 daNm). Refit the accessories belt (see 11A, Top and front of engine, accessories belt).
11A-28
TOP AND FRONT OF ENGINE Cylinder head gasket

L90, and K7J, and 710 Essential special tooling
11A
DIRECTION ASSISTEE, and AIR CONDITIONING Mot. 1672 Mot. 1202-01 Lower engine support Clip pliers for cooling system hose clips (large model) Clip pliers for cooling system hose clips (small model) Remote operation pliers for cooling system hose clips Essential equipment cylinder head testing tool
Mot. 1202-02
Mot. 1448
Tightening torques m cylinder head mounting bolts rocker cover mounting bolts multifunction support mounting bolts 220 10
1
108649
1 daNm 2.1 daNm
Remove mounting bolt (1) from the multifunction support.
REMOVAL
Place the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal.
109492
Set up engine support tool (Mot. 1672). Remove: - the accessories belt (see 11A, Top and front of engine, Accessories belt ). - the timing belt (see 11A, Top and front of engine, Timing belt), Drain the cooling circuit via the bottom hose using tool (Mot. 1202-01), tool (Mot. 1202-02) or tool (Mot. 1448).
11A-29

11A
108423
107358
Remove mounting bolts (2) from of the air filter box.
Disconnect connector (4) of the ignition coil. Remove the ignition spark plug leads. Note: The ignition spark plug leads are marked on the ignition coil (cylinder number 1 engine ywheel end).
3 6
107361
Disconnect: - oil vapour rebreather pipe (3) from the base of air filter box, - the air suction sleeve on the body. Remove the air filter box.
5
107486
Remove the inlet manifold reinforcement stay located between cylinder block and inlet manifold (5). Disconnect fuel supply pipe (6) on the injection rail. IMPORTANT Be careful of petrol splashing out when disconnecting the fuel supply union. Wear gloves during the operation.
11A-30

11A
- pipe (12) from the brake servo on the inlet manifold, - petrol vapour rebreather pipe (13) from the inlet manifold. Disconnect:
- ball joint (14) from the throttle valve control cable, - cable sleeve stop (15) from the throttle valve control cable.
16
107357
15
12
14 9 11
108565
Disconnect the three cooling hoses (16) with tool (Mot. 1202-01), tool (Mot. 1202-02) or tool (Mot. 1448).
10 13
107356
Disconnect: - the injector connectors, - connector (7) from the idle speed control motor, - connector (8) from the throttle valve position sensor, - connector (9) from the inlet air temperature sensor, - connector (10) from the supply air depression sensor, - connector (11) from the coolant temperature sensor,
11A-31

11A
17
10016
Remove: - the rocker cover mounting bolts, - the rocker cover.

109493
Remove: - the earth cable from the lifting eye, - hose support mounting (17) on the lifting eye.
10015
Remove:
19 18
- the cylinder head mounting bolts, - the cylinder head-inlet manifold assembly, - the cylinder head gasket.
109216
Remove retaining bolt (18) from the dipstick guide tube. Unhook electrical harness (19). Remove the exhaust manifold (see 12A, Burnt mixture, Exhaust manifold).
11A-32

L90, and K7J, and 710 I -CLEANING THE CYLINDER HEAD Clean the cylinder head. IMPORTANT - Do not scratch the aluminium gasket faces. - Wear goggles. - Wear gloves during the operation. - Clean the gasket faces with DECAPJOINT to dissolve any seals which are still cemented. - Apply the product to the section to be cleaned; Wait approximately ten minutes, then remove the residue using a wooden spatula. WARNING WARNING
11A
REFITTING
In order to ensure that the bolts are correctly tightened, use a syringe to remove any oil which may be in the cylinder head mounting holes.
Be sure to replace all seals that have been removed. Bring the pistons to mid-stroke position to prevent them from coming into contact with the valves during the tightening of the cylinder head. Fit the cylinder head with a new gasket.
WARNING Do not allow this product to drip onto the paintwork. Clean the cylinder head carefully to prevent foreign bodies from entering the oil inlet and return pipes. Failure to follow this advice could lead to the blocking of the various oil inlet ducts, which would quickly result in engine damage.
9 5 1 4
WARNING All cylinder head bolts must always be changed after removal. II - CHECKING THE GASKET FACE With a ruler and shim set, check for gasket face bow. The maximum deformation is 0.05 mm.
8 6 2 3 7
10
WARNING No regrinding of the cylinder head is permitted. Tightening the cylinder head: Test the cylinder head for any cracks using the cylinder head testing tool (see Garage Equipment Catalogue). Refer to Technical Note 6010A for the cylinder head stripping down procedure.
107772
- Pretighten in order and to torque the cylinder head mounting bolts (2 daNm), - Check that all the cylinder head mounting bolts are properly tightened to 2 daNm, - angle tighten in order the cylinder head mounting bolts (220 10) .
WARNING Do not retighten the cylinder head bolts after applying this procedure.
11A-33

11A
5
10016
Fit the rocker cover with a new gasket. Tightening the rocker cover: - pretighten in order and to torque the rocker cover mounting bolts (0.2 daNm). - Torque tighten in order the rocker cover mounting bolts (1 daNm) . Refit: - the timing belt (see 11A, Top and front of engine, Timing belt), - the accessories belt (see 11A, top and front of engine, Accessories belt ) - the exhaust manifold (see 11A, Top and front of engine, Exhaust manifold).
DIRECTION ASSISTEE, and AIR CONDITIONING Torque tighten the multifunction support mounting bolts (2.1 daNm).
Proceed in the reverse order to removal.
WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery, Battery: Removal - Retting ). Fill up and bleed the cooling circuit (see 19A, Cooling, Draining - Filling the cooling circuit).
11A-34

L90, and K7M, and 710 Essential special tooling
11A
DIRECTION ASSISTEE, and AIR CONDITIONING Mot. 1672 Mot. 1202-01 Lower engine support Clip pliers for cooling system hose clips (large model) Clip pliers for cooling system hose clips (small model) Remote operation pliers for cooling system hose clips Essential equipment cylinder head testing tool
Mot. 1202-02
Mot. 1448
Tightening torques m cylinder head mounting bolts rocker cover mounting bolts multifunction support mounting bolts 220 10
1
108649
1 daNm 2.1 daNm
Remove mounting bolt (1) from the multifunction support.
REMOVAL
Place the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal.
109492
Set up engine support tool (Mot. 1672). Remove: - the accessories belt (see 11A, Top and front of engine, Accessories belt ). - the timing belt (see 11A, Top and front of engine, Timing belt), Drain the cooling circuit via the bottom hose using tool (Mot. 1202-01), tool (Mot. 1202-02) or tool (Mot. 1448).
11A-35

11A
108423
107358
Remove mounting bolts (2) from of the air filter box.
Disconnect connector (4) of the ignition coil. Remove the ignition spark plug leads. Note: The ignition spark plug leads are marked on the ignition coil (cylinder number 1 engine ywheel end).
3 6
107361
Disconnect: - oil vapour rebreather pipe (3) from the base of air filter box, - the air suction sleeve on the body. Remove the air filter box.
5
107486
Remove the inlet manifold reinforcement stay located between the cylinder block and inlet manifold (5). Disconnect fuel supply pipe (6) on the injection rail. IMPORTANT Be careful of petrol splashing out when disconnecting the fuel supply union. Wear gloves during the operation.
11A-36

11A
- pipe (12) from the brake servo on the inlet manifold, - petrol vapour rebreather pipe (13) from the inlet manifold. Disconnect:
- ball joint (14) from the throttle valve control cable, - cable sleeve stop (15) from the throttle valve control cable.
16
107357
15
12
14 9 11
108565
Disconnect the three cooling hoses (16) with tool (Mot. 1202-01), tool (Mot. 1202-02) or tool (Mot. 1448).
10 13
107356
Disconnect: - the injector connectors, - connector (7) from the idle speed control motor, - connector (8) from the throttle valve position sensor, - connector (9) from the inlet air temperature sensor, - connector (10) from the supply air depression sensor, - connector (11) from the coolant temperature sensor,
11A-37

11A
17
10016
Remove: - the rocker cover mounting bolts, - the rocker cover.

109493
Remove: - the earth cable from the lifting eye, - hose support mounting (17) on the lifting eye.
10015
Remove:
19 18
- the ten cylinder head mounting bolts, - the cylinder head-inlet manifold assembly, - the cylinder head gasket.
109216
Remove retaining bolt (18) from the dipstick guide tube. Unhook the electrical harness (19) . Remove the exhaust manifold (see 12A, Burnt mixture, Exhaust manifold).
11A-38

L90, and K7M, and 710 I -CLEANING THE CYLINDER HEAD Clean the cylinder head. IMPORTANT - Do not scratch the aluminium sealing surfaces. - Wear goggles. - Wear gloves during the operation. - Clean the gasket faces with DECAPJOINT to dissolve any seals which are still cemented. - Apply the product to the section to be cleaned; Wait approximately ten minutes, then remove the residue using a wooden spatula. WARNING WARNING
11A
REFITTING
In order to ensure that the bolts are correctly tightened, use a syringe to remove any oil which may be in the cylinder head mounting holes.
Be sure to replace all seals that have been removed. Bring the pistons to mid-stroke position to prevent them from coming into contact with the valves during the tightening of the cylinder head. Fit the cylinder head with a new gasket.
WARNING Do not allow this product to drip onto the paintwork. Clean the cylinder head carefully to prevent foreign bodies from entering the oil inlet and return pipes. Failure to follow this advice could lead to the blocking of the various oil inlet ducts, which would quickly result in engine damage.
9 5 1 4
WARNING All cylinder head bolts must always be changed after removal. II - CHECKING THE GASKET FACE With a ruler and shim set, check for gasket face bow. The maximum deformation is 0.05 mm.
8 6 2 3 7
10
WARNING No regrinding of the cylinder head is permitted. Tightening the cylinder head: Test the cylinder head for any cracks using the cylinder head testing tool (see Garage Equipment Catalogue). Refer to Technical Note 6010A for the cylinder head stripping down procedure.
107772
- Pretighten in order and to torque the cylinder head mounting bolts (2 daNm), - Check that all the cylinder head mounting bolts are properly tightened to 2 daNm, - angle tighten in order the cylinder head mounting bolts (220 10) .
WARNING Do not retighten the cylinder head bolts after applying this procedure.
11A-39

11A
5
10016
Fit the rocker cover with a new gasket. Tightening of the rocker cover: - Pretighten in order and to torque the rocker cover mounting bolts (0.2 daNm), - Torque tighten in order the rocker cover mounting bolts (1 daNm) . Refit: - the timing belt (see 11A, Top and front of engine, Timing belt), - the accessories belt (see 11A, top and front of engine, Accessories belt ) - the exhaust manifold (see 11A, Top and front of engine, Exhaust manifold).
DIRECTION ASSISTEE, and AIR CONDITIONING Torque tighten the multifunction support mounting bolts (2.1 daNm).
WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery, Battery: Removal - Retting ). Fill up and bleed the cooling circuit (see 19A, Cooling, Draining - Filling the cooling circuit).
11A-40
FUEL MIXTURE Specifications

K7J, and 710
12A
Fuel
(2)
Test carried out at idle speed (1) Engine Vehicle type Pollutant emissions (3) Type Sufx Depollution standard Idling speed (rpm) CO (%)
(4)
CO2 (%)
HC (ppm)
Lambda ( )
(minimum octane rating)
LS0A LS0C Without OBD

(1)
K7J
710
Euro 3
752 +/40
0.5 maximum
(3) (4)
14.5 maximum 100
0.97 < < 1.03
Super unleaded (Octane rating 95)
for a coolant temperature above 80C and after the engine speed has stabilised at 2,500 rpm for 30 seconds approx.
(2)
for the legal values, see specifications by country at 2000 rpm CO should be 0.3 % maximum
octane rating 91 unleaded compatible -40 49930 6790 75780 6970 -10 9540 10440 12460 1121 25 2050 123 2250 112 50 810 47 810 38 80 309 17 110 135 8 114 3 120 105 7 87 2
Temperatures in C +/- 1 Negative temperature coefcient air temperature sensor (resistance in ) Negative temperature coefcient coolant temperature sensor (resistance in )
280 9
Description Injection computer Ignition coils
Brand - Type SIEMENS-SIRIUS 32 JCAE
Special notes 90-track computer Dual-output single unit coils 4-track connector - A: cylinder coil controls 1 and 4 - B: cylinder coil controls 2 and 3 - C: + 12 V supply - D: not wired
Injectors
BOSCH EV14
Resistance: 12 at 20C 2 track connector - 1: supply - 2: earthing
12A-1

K7J, and 710 Description Manifold pressure sensor Brand - Type SIEMENS 5WK9681 Special notes Piezo-resistive sensor 3-track connector: - A: earth - B: signal - C: + 5 V supply Injection order Fault nding Throttle potentiometer Fault nding tool CTS 1, 3, 4, 2 (number 1 ywheel end) CLIP only 3-track connector: - A: earth - B: + 5 V supply - C: signal Track resistance: 1200 240 Pinking sensor JCAE Piezoelectric type sensor Tightening torque: 20 Nm Engine speed and position sensor Upstream oxygen sensor SIEMENS Integrated connector Resistance: 200 to 270 NTK 6 L
12A
The sensor heating is interrupted when the exhaust gas temperature rises above 650C. Heating resistor: 3.3 at 20C 4-track connector - A: heating resistor supply - B: heating resistor earth - C: + signal - D: - signal Warm engine: - Rich mixture >850 mV - Lean mixture <100 mV
12A-2

K7J, and 710 Description Downstream oxygen sensor Brand - Type NTK 6 L Special notes
12A
The sensor heating is interrupted when the exhaust gas temperature rises above 650C. Heating resistor: 6 at 20C 4-track connector - A: heating resistor supply - B: heating resistor earth - C: + signal - D: - signal Warm engine: - Rich mixture >850 mV - Lean mixture <100 mV
Fuel vapour absorber solenoid valve
JCAE
Built into the fuel vapour absorber Resistance: 26 4 at 20C 2-track connector - 1: supply - 2: earthing
Coolant temperature sensor Air temperature sensor
SYLEA DAV IATS 04 CHAMPION RYCLC87
Negative temperature coefcient thermistor (see previous table) Negative temperature coefcient thermistor (see previous table)
Spark plugs SAGEM RFN58LZ Refrigerant pressure sensor TEXAS INSTRUMENT
Gap: 0.95 0.05 mm Torque: 25 to 30 Nm
3-track connector: - A: earth - B: + 5 V supply - C: signal
Vehicle speed sensor
HALMO
3-track connector: - A: supply - B1: signal - B2: earth
Power assisted steering pressostat
TEXAS INSTRUMENT
Contact: open to the rest position
12A-3

K7M, and 710
12A
Fuel
(2)
Test carried out at idle speed (1) Engine Vehicle type Pollutant emissions (3) Type Sufx Emission control Idling speed (rpm) 0.5 maximum
(3) (4)
(minimum Lambda ( ) octane rating)
CO (%)
(4)
CO2 (%)
HC (ppm)
LS0B LS0D Without OBD

(1)
K7M
710
Euro 3
752 +/40
14.5 maximum 100
0.97 < < 1.03
Super unleaded (Octane rating 95)
for a coolant temperature above 80C and after the engine speed has stabilised at 2,500 rpm for 30 seconds approx.
(2)
for the legal values, see specifications by country at 2000 rpm CO should be 0.3 % maximum
octane rating 91 unleaded compatible -40 49930 6790 75780 6970 -10 9540 10440 12460 1121 25 2050 123 2250 112 50 810 47 810 38 80 309 17 110 135 8 114 3 120 105 7 87 2
Temperatures in C +/- 1 Negative temperature coefcient air temperature sensor (resistance in ) Negative temperature coefcient coolant temperature sensor (resistance in )
280 9
Description Injection computer Ignition coils
Brand - Type SIEMENS-SIRIUS 32 JCAE
Special notes 90-track computer Dual-output single unit coils 4-track connector - A: cylinder coil controls 1 and 4 - B: cylinder coil controls 2 and 3 - C: + 12 V supply - D: not wired
Injectors
BOSCH EV14
Resistance: 12 at 20C 2-track connector - 1: supply - 2: earthing
12A-4

K7M, and 710 Description Manifold pressure sensor Brand - Type SIEMENS 5WK9681 Special notes Piezo-resistive sensor 3-track connector: - A: earth - B: signal - C: + 5 V supply Injection order Fault nding Throttle potentiometer Diagnostic tool CTS 1, 3, 4, 2 (number 1 ywheel end) CLIP only 3-track connector: - A: earth - B: + 5 V supply - C: signal Track resistance: 1200 240 Pinking sensor JCAE Piezoelectric type sensor Tightening torque: 20 Nm Engine speed and position sensor Upstream oxygen sensor SIEMENS Integrated connector Resistance: 200 to 270 NTK 6 L
12A
The sensor heating is interrupted when the exhaust gas temperature rises above 650C. Heating resistor: 3.3 at 20C 4-track connector - A: heating resistor supply - B: heating resistor earth - C: + signal - D: - signal Warm engine: - Rich mixture >850 mV - Lean mixture <100 mV
12A-5

K7M, and 710 Description Downstream oxygen sensor Brand - Type NTK 6 L Special notes
12A
The sensor heating is interrupted when the exhaust gas temperature rises above 650C. Heating resistor: 6 at 20C 4-track connector - A: heating resistor supply - B: heating resistor earth - C: + signal - D: - signal Warm engine: - Rich mixture >850 mV - Lean mixture <100 mV
Petrol vapour absorber solenoid valve
JCAE
Built into the petrol vapour absorber Resistance: 26 4 at 20C 2-track connector - 1: supply - 2: earthing
Coolant temperature sensor Air temperature sensor
SYLEA DAV IATS 04 CHAMPION RYCLC87
Negative temperature coefcient thermistor (see previous table) Negative temperature coefcient thermistor (see previous table)
Spark plugs SAGEM RFN58LZ Refrigerant pressure sensor TEXAS INSTRUMENT
Gap: 0.95 0.05 mm Torque: 25 to 30 Nm
3-track connector: - A: earth - B: + 5 V supply - C: signal
Vehicle speed sensor
HALMO
3-track connector: - A: supply - B1: signal - B2: earth
Power assisted steering pressostat
TEXAS INSTRUMENT
Contact: open to rest position
12A-6
FUEL MIXTURE Air inlet

K7J, and 710
12A
2 3
1202
( 1) ( 2) ( 3)
Air lter unit Throttle valve intake manifold
12A-7
FUEL MIXTURE Air inlet

K7M, and 710
12A
1202
( 1) ( 2) ( 3)
Air lter unit Throttle valve intake manifold
12A-8
FUEL MIXTURE Air filter: Replacement

K7J, and 710
12A
REMOVAL
107574
Remove the air filter unit cover mounting bolts. Unfasten the cover mounting clips. Remove: - the air filter unit cover, - the air filter.
REFITTING
12A-9
FUEL MIXTURE Air filter: Replacement

K7M, and 710
12A
REMOVAL
107574
Remove the air filter unit cover mounting bolts. Unfasten the cover mounting clips. Remove: - the air filter unit cover, - the air filter.
REFITTING
12A-10
FUEL MIXTURE Air filter unit

K7J, and 710
12A
REMOVAL
1
1
108423
Remove the air filter unit mounting bolts (1).
107361
Disconnect: - the oil vapour rebreather pipe (2), - the air inlet sleeve. Remove the air filter unit.
REFITTING
12A-11
FUEL MIXTURE Air filter unit

K7M, and 710
12A
REMOVAL
1
1
108423
Remove the air filter unit mounting bolts (1).
107361
REFITTING
12A-12
FUEL MIXTURE Inlet manifold

K7J, and 710
12A
Tightening torques m inlet manifold mounting bolts inlet manifold mounting nuts 2.5 daNm 2.5 daNm
3 5
REMOVAL
Mount the vehicle on a two post lift. Disconnect the battery, starting with the negative terminal.
1
107356
Unclip the ball joints (3 ). Disconnect: - the temperature sensor (4), - the pressure sensor (5), - the brake servo pipe from the inlet manifold,
1
108423
- pipe (6 ) from the inlet manifold, - the petrol vapour rebreathing pipe from the inlet manifold.
Remove mounting bolts (1) from the air filter unit.
107361
12A-13

K7J, and 710
12A
IMPORTANT During this operation, be sure to: - refrain from smoking or bringing very hot objects near the working area, - beware of fuel splashing when disconnecting the union, - protect sensitive areas from fuel outow. Disconnect the injector connectors.
107357
Disconnect: - the throttle potentiometer sensor connector , - the idling speed stepper motor connector (7). Remove the throttle valve by tilting it. DIRECTION MANUELLE Disconnect the fuel supply pipe (8) from the injection rail. WARNING Before starting work, protect the alternator with plastic bags.
IMPORTANT Wear gloves during the operation.
DIRECTION ASSISTEE Disconnect the fuel supply pipe (8) from the injection rail. IMPORTANT Wear gloves during the operation.
12A-14

K7J, and 710
12A
Always replace all seals that have been removed.
REFITTING
11
13
12
10 9
107486
107777
Refit the inlet manifold, starting with the centre lower mounting nut (13). Torque tighten: - the inlet manifold mounting bolts (2.5 daNm),
12
- the inlet manifold mounting nuts (2.5 daNm). Proceed in the reverse order to removal. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery, Battery: Removal - Retting ).
107777
Remove the inlet manifold mounting bolts from bracket (9). Unclip the inlet manifold electrical harness (10). Remove the inlet manifold upper mounting bolts (11). Remove lower mounting nuts (12) from the inlet manifold (from below).
Note: In order to completely remove the bottom centre mounting nut: - remove the outer nuts, - remove the manifold from the cylinder head. Remove the inlet manifold.
12A-15

K7M, and 710
12A
Tightening torques m inlet manifold mounting bolts inlet manifold mounting nuts 2.5 daNm 2.5 daNm
REMOVAL
Mount the vehicle on a two post lift. Disconnect the battery, starting with the negative terminal.
6 1
107356
Unclip the ball joints (3 ). Disconnect: - the temperature sensor (4), - the pressure sensor (5), - the brake servo pipe from the inlet manifold,
1
108423
- pipe (6 ) from the inlet manifold, - the petrol vapour rebreathing pipe from the inlet manifold.
Remove mounting bolts (1) from the air filter unit.
107361
12A-16

K7M, and 710
12A
IMPORTANT During this operation, be sure to: - refrain from smoking or bringing hot objects near the working area, - beware of fuel splashing when disconnecting the union, - protect sensitive areas from fuel outow. Disconnect the injector connectors.
107357
Disconnect: - the throttle potentiometer sensor connector , - the idling speed stepper motor connector (7). Remove the throttle valve by tilting it. DIRECTION MANUELLE Disconnect the fuel supply pipe (8) from the injection rail. WARNING Before starting work, protect the alternator with plastic bags.
DIRECTION ASSISTEE Disconnect the fuel supply pipe (8) from the injection rail. IMPORTANT Wear gloves during the operation.
12A-17

K7M, and 710
12A
Always replace all seals that have been removed.
REFITTING
11
13
12
10
9
107486
107777
Refit the inlet manifold, starting with the centre lower mounting nut (13). Torque tighten: - the inlet manifold mounting bolts (2.5 daNm),
12
- the inlet manifold mounting nuts (2.5 daNm). Proceed in the reverse order to removal. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery, Battery: Removal - Retting ).
107777
Remove the inlet manifold mounting bolts from bracket (9). Unclip the inlet manifold electrical harness (10). Remove the inlet manifold upper mounting bolts (11). Remove lower mounting nuts (12) from the inlet manifold (from below).
Note: In order to completely remove the bottom centre mounting nut: - remove the outer nuts, - remove the manifold from the cylinder head. Remove the inlet manifold.
12A-18
FUEL MIXTURE Exhaust manifold

K7J, and 710
12A
Tightening torques m exhaust manifold mounting nuts exhaust d ownpipe mounting studs exhaust d ownpipe mounting nuts 2.5 daNm 0.7 daNm 2.1 daNm
REMOVAL
Mount the vehicle on a two post lift.
2
108427
Disconnect the oxygen sensor connector. Remove:
- the two exhaust downpipe mountings ( 2), - the exhaust manifold - cylinder head mountings, - the exhaust manifold.
REFITTING
108425
Remove the heat shield mountings (1).
109399
WARNING You must replace the exhaust bushing betw een the exhaust manifold and the catalytic converter. Always replace all seals that have been removed. Refit the new seal on the exhaust manifold.
12A-19

K7J, and 710
12A
1 3
6 4 5 7
108427
Torque tighten in order the exhaust manifold mounting nuts (2.5 daNm). Torque tighten: - the exhaust downpipe mounting studs (0.7 daNm) (if studs removed), - the exhaust downpipe mounting nuts (2.1 daNm). Proceed in the reverse order to removal.
12A-20

K7M, and 710
12A
Tightening torques m exhaust manifold mounting nuts exhaust d ownpipe mounting studs exhaust d ownpipe mounting nuts 2.5 daNm 0.7 daNm 2.1 daNm
REMOVAL
Mount the vehicle on a two-post lift.
2
108427
Disconnect the oxygen sensor connector. Remove:
- the two exhaust downpipe mountings ( 2), - the exhaust manifold - cylinder head mountings, - the exhaust manifold.
REFITTING
108425
Remove the heat shield mountings (1).
109399
WARNING You must replace the exhaust bushing betw een the exhaust manifold and the catalytic converter. Always replace all seals that have been removed. Refit the new seal on the exhaust manifold.
12A-21

K7M, and 710
12A
1 3
5 7
108427
Torque tighten in order the exhaust manifold mounting nuts (2.5 daNm). Torque tighten: - the exhaust downpipe mounting studs (0.7 daNm) (if studs removed), - the exhaust downpipe mounting nuts (2.1 daNm). Proceed in the reverse order to removal.
12A-22
FUEL MIXTURE Throttle valve

K7J, and 710
12A
3
REMOVAL
1
1
108423
Remove the air filter box (1) mounting bolts.
107356
Unclip the ball joint (3 ).
4 2 5
107361
Disconnect: - the oil vapour rebreather pipe (2), - the air inlet sleeve. Remove the air filter box.
107357
Disconnect: - the throttle position sensor connector (4), - the idling speed stepper motor connector (5). Remove the throttle valve by tilting it.
REFITTING
Always replace all seals that have been removed. Proceed in the reverse order to removal.
12A-23
FUEL MIXTURE Throttle valve

K7M, and 710
12A
3
REMOVAL
1
1
108423
Remove the air filter box (1) mounting bolts.
107356
Unclip the ball joint (3 ).
4 2 5
107361
Disconnect: - the oil vapour rebreather pipe (2), - the air inlet sleeve. Remove the air filter box.
107357
Disconnect: - the throttle position sensor connector (4), - the idling stepper motor connector (5). Remove the throttle valve by tilting it.
REFITTING
12A-24
FUEL MIXTURE Throttle body: Connection

K7M, and 710
12A
A A C D
109393
To connect the throttle valve, see Technical Note Wiring Diagrams, Components 222 and 649.
12A-25
FUEL MIXTURE Throttle body: Connection

K7J, and 710
12A
A A C D
109393
For information on connecting the throttle valve, see Technical Note: Wiring diagrams, Components 222 and 649.
12A-26
FUEL SUPPLY Petrol supply circuit

K7J, and 710 K7M, and 710 Operating diagram of the petrol supply circuit
13A
2 4
1 3
19310
The fuel system does not have a return. The fuel pressure does not vary with engine load. The circuit comprises: - a petrol "pump-gauge-filter" supply unit fitted with a fuel filter (1), a pump (2) and a pressure regulator (3 ) (all located in the tank), - a single pipe (4) coming from the tank, - a rail (5) without a return pipe and without a supply pressure regulator, - a fuel vapour recirculation tank (6).
13A-1
FUEL SUPPLY Injector rail - Injectors

K7J, and 710
13A
3
Tightening torques m injection rail mounting bolts 0.7 daNm
REMOVAL
Disconnect the battery, starting with the negative terminal.
1 4
107357
Disconnect:
1
108423
- the injector connectors, - the throttle position sensor connector (3).
Remove the air filter box (1) mounting bolts. DIRECTION MANUELLE Disconnect the fuel inlet pipe (4) on the injector rail.
WARNING Before the operation, protect the alternator with plastic bags.
107361
Disconnect: - the oil vapour rebreather pipes (2), - the air inlet sleeve. Remove the air filter box. DIRECTION ASSISTEE Disconnect the fuel inlet pipe (4) on the injector rail.
13A-2

K7J, and 710
13A
Proceed in the reverse order to removal. IMPORTANT During this operation, it is essential to: - refrain from smoking or bringing incandescent objects close to the work area, - beware of fuel splashes when disconnecting the union, - protect sensitive areas from fuel outow. Remove: - the rail mounting bolts. - the injection rail. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery, Battery: Remove and Ret).
101473
Remove: - clips (5 ), - the injectors.
REFITTING
Replace the O rings at the base of the injector (if the injector has been removed, also replace the seal which is level with the injector head). Check for the click of the fuel unions when connecting. Torque tighten the injection rail mounting bolts (0.7 daNm).
13A-3

K7M, and 710
13A
3
Tightening torques m injection rail mounting bolts 0.7 daNm
REMOVAL
1 4
107357
Disconnect:
1
108423
- the injector connectors, - the throttle position sensor connector (3).
Remove the air filter box (1) mounting bolts. DIRECTION MANUELLE Disconnect the fuel inlet pipe (4) on theinjection rail.
WARNING Before the operation, protect the alternator with plastic bags.
107361
Disconnect: - the oil vapour rebreather pipes (2), - the air inlet sleeve. Remove the air filter box. DIRECTION ASSISTEE Disconnect the fuel inlet pipe (4) on theinjection rail.
13A-4

K7M, and 710
13A
Proceed in the reverse order to removal. IMPORTANT During this operation, it is essential to: - refrain from smoking or bringing incandescent objects close to the work area, - beware of fuel splashes when disconnecting the union, - protect sensitive areas from fuel leakage. Remove: - the rail mounting bolts, - the injection rail. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery, Battery: Remove and Ret).
101473
Remove: - the clips (5), - the injectors.
REFITTING
Replace the O rings at the base of the injector (if the injector has been removed, also replace the seal which is level with the injector head). Check for the click of the fuel unions when connecting. Torque tighten the injection rail mounting bolts (0.7 daNm).
13A-5
FUEL SUPPLY Fuel pressure regulator:Checking

K7J or K7M, and 710 Essential special tooling Mot. 1311-08 Mot. 1311-01 Union for measuring fuel pressure Fuel pressure pressure gauges and socket unions
13A
IMPORTANT During this operation, be sure to: - refrain from smoking or bringing hot objects near the working area, - beware of fuel splashes when disconnecting the union, - protect sensitive areas from fuel outow.
109173
Connect: - T union (Mot. 1311-08)(3) to the pipe coming from the fuel tank, - pipe (2 ) fitted with a pressure gauge and contained in test kit (Mot. 1311-01) to T union (3), - the fuel supply pipe to T union (3 ). Start the vehicle to activate the fuel pump. Determine the pressure: - the pressure must be constant (approximately 3.5 bar ).
108650
- It may take a few seconds to obtain a correct pressure reading.
Disconnect fuel supply pipe union (1). IMPORTANT Wear gloves during the operation.
13A-6
FUEL SUPPLY Electric fuel: Checking

13A
IMPORTANT During this operation, be sure to: - refrain from smoking or bringing very hot objects close to the working area, - beware of fuel splashes when disconnecting the union, - protect sensitive areas from fuel outow.
109173
Connect: - the "T" union (Mot. 1311-08)(3) to the tank outlet pipe,
- the pipe (2 ) that comes from the test kit (Mot. 131101) to the "T" union ( 3), - the petrol supply pipe to the "T" union (3 ).
108650
Disconnect the petrol supply pipe union (1). IMPORTANT Wear gloves during the operation.
13A-7
FUEL SUPPLY Electric fuel: Checking

K7J or K7M, and 710
13A
8 5 1
109172
Connect the connector terminal ( 5 ) to + battery feed . Note the time taken for the measuring cylinder to fill up.
109174
Immerse the pipe (2) in a 2 l measuring cylinder. IMPORTANT This procedure must be carried out with the ignition off.
Note: The minimum pump ow is 60 l/h.
109171
Disconnect the engine-passenger compartment electric wiring harness connector (5).
13A-8
ANTIPOLLUTION Petrol vapour rebreathing: Operation

K7J or K7M, and 710 I -OPERATING DIAGRAM OF THE CIRCUIT
14A
4 7 5 3 6 2 6 1 2 5 7 3
108415 97393
II - OPERATING PRINCIPLE ( 1) ( 2) ( 3) ( 4) ( 5) ( 6) ( 7) Tank Fuel vapour absorber Fuel vapour absorber bleed solenoid valve Intake manifold Breather Recirculation of fuel vapour from the tank Rebreathing of fuel vapours going to the engine The tank is vented by means of the fuel vapour absorber. Fuel vapour is trapped by the active charcoal contained in the absorber as it passes through. Fuel vapour trapped in the absorber is eliminated and burnt by the engine. To do this, the fuel vapour absorber and inlet manifold are connected via the solenoid valve. This solenoid valve is integrated in the fuel vapour absorber. The principle behind the solenoid valve is to open a passage of variable size (according to the opening cyclic ratio signal sent by the injection computer). The variation in the passage opened for fuel vapour in the solenoid valve results from the balance between the magnetic field created by the supply to the winding and the return spring force attempting to close the solenoid valve.
14A-1
ANTIPOLLUTION Fuel vapour rebreathing: Checking

K7J or K7M, and 710
14A
Essential equipment diagnostic tool I -CHECKING THE OPERATION OF THE FUEL VAPOUR ABSORBER BLEED
II - FUEL VAPOUR ABSORBER BLEEDING CONDITIONS The fuel vapour absorber bleed solenoid valve is controlled by track 4 of the computer connector when: - the coolant temperature is above 60C, - the air temperature is above 10C, - the engine is not at idling speed,
Note: A fault with this system may result in rough idling or the engine stalling.
- a given load threshold is reached, - the throttle potentiometer is not in the no load position. During on board diagnostic fault finding, fuel vapour absorber bleeding is not authorised.
It is possible to display the opening cyclic ratio of the fuel vapour absorber bleed solenoid valve using the diagnostic tool by referring to parameter PR023: canister bleed solenoid valve OCR . The solenoid valve is closed at values below 3 %.
5 3
1
97393
( 1) ( 2) ( 3) ( 4) ( 5)
Tank Fuel vapour absorber Fuel vapour absorber bleed solenoid valve Intake manifold Breather
Check the conformity of the circuit (see 14A, Antipollution, Fuel vapour rebreathing: Operation). Check the condition of the pipes to the tank.
14A-2
ANTIPOLLUTION Fuel vapour canister

K7J or K7M, and 710
14A
Tightening torques m fuel vapour absorber mounting nuts 21 Nm
The fuel vapour absorber is located behind the front bumper on the right-hand side of the vehicle.
REMOVAL
Mount the vehicle on a lift. Remove the plastic screen from underneath the fuel vapour absorber. Remove: - fuel vapour absorber mounting nuts (3), - the fuel vapour absorber.
3
108428
REFITTING
2 1
Proceed in the reverse order to removal. Torque tighten the fuel vapour absorber mounting nuts (21 Nm).
108415
Disconnect: - pipes (1 ) from the fuel vapour absorber (without removing the bumper), - the solenoid valve connector. Unclip breather pipe (2).
14A-3
ANTIPOLLUTION Fuel vapour canister:Checking

K7J or K7M, and 710 Essential special tooling Mot. 1311-01 Fuel pressure pressure gauges and socket unions Essential equipment diagnostic tool
14A
No: there is an electrical fault, check the circuit. - If not: under the conditions required for bleeding (see 14A, Antipollution, Fuel vapour rebreathing ), the vacuum pressure should increase (the value of parameter: PR023 canister bleed solenoid valve OCR on the diagnostic tool should increase at the same time).
CHECKING THE FUEL VAPOUR ABSORBER TANK CONNECTION

Check this connection by connecting a vacuum pump to the pipe going to the absorber.
CHECKING THE FUEL VAPOUR ABSORBER

On the fuel vapour absorber, plug the circuit coming from the fuel tank.
108415
Connect the pressure gauge of tool (Mot. 1311-01) to absorber breather outlet (1). With the engine at idle speed, check that no vacuum is present at the absorber breather outlet. Under the same conditions, the control value read by the diagnostic tool in parameter: PR023 canister bleed solenoid valve OCR remains minimal (lower than or equal to 3 %. Is there a vacuum? - If so: with the ignition off, use a vacuum pump to apply a vacuum of 500 mbar to the solenoid valve outlet . The vacuum pressure should not vary by more than 10 mbar over 30 seconds . Does the pressure vary? Yes: the solenoid valve is faulty; replace the fuel vapour absorber (the solenoid valve is integrated in the fuel vapour absorber).
14A-4
STARTING - LOAD Alternator: General information

K7J or K7M, and 710 I -OPERATION These vehicles are equipped with an internal ventilation alternator with integrated regulator, and a warning light on the instrument panel that works as follows: - the warning light lights up when the ignition is switched on, Engine K7J 710 DM K7M 710 DM K7J 710 PAS K7M 710 PAS K7J 710 MS/AC K7M 710 MS/AC K7J 710 PAS/AC K7M 710 PAS/AC III - CHECKING Alternator minimum guaranteed flows under 13.5 V after 15 minutes of heating with the engine running and electrical consumers switched on. Engine speed MELCO 70 A rpm 1000 2000 3000 4000 A 55 72 77 79,5 VALEO 75 A A 53 73 75 79 MELCO 110 A A 80 108 116 120 BOSCH: 0124415014 100 A MELCO: A002TC0391 110 A VALEO: SG7 S013 75 A Alternator MELCO: A001TA3792
16A
- the light goes out when the engine is switched off, - if the indicator light comes on while the engine is running, it indicates a battery charge fault. II - IDENTIFICATION
Current strength 70 A
BOSCH 100 A A 71 96 99 100
16A-1
STARTING - LOAD Alternator

K7J, and 710, and DIRECTION MANUELLE
16A
REFITTING
Tightening torques m alternator mounting bolt alternator mounting bolt 2.1 daNm 4.4 daNm WARNING When replacing the belt, be sure to replace the tension wheels and idler pulleys. Proceed in the reverse order to removal. Refit the accessories belt(s) (see 11A, Top and front of engine, Accessories belt), WARNING Replace any belt that has been removed.
REMOVAL
Torque tighten: - the alternator mounting bolt (2.1 daNm), - the alternator mounting bolt (4.4 daNm).
109237
Remove: - the accessories belt(s) (see 11A, Top and front of engine, Accessories belt), - the engine undertray. Disconnect the wiring harnesses from the alternator. Remove (from below): - the mounting bolt (1), - mounting bolt (2 ), - the alternator.
16A-2

K7M, and 710, and DIRECTION MANUELLE
16A
REFITTING
Tightening torques m alternator mounting bolt alternator mounting bolt 2.1 daNm 4.4 daNm WARNING When replacing the belt, be sure to replace the tension wheels and idler pulleys. Proceed in the reverse order to removal. Refit the accessories belt(s) (see 11A, Top and front of engine, Accessories belt), WARNING Replace any belt that has been removed.
REMOVAL
Torque tighten: - the alternator mounting bolt (2.1 daNm), - the alternator mounting bolt (4.4 daNm).
109237
Remove: - the accessories belt(s) (see 11A, Top and front of engine, Accessories belt), - the engine undertray. Disconnect the wiring harnesses from the alternator. Remove (from below): - the mounting bolt (1), - mounting bolt (2 ), - the alternator.
16A-3

K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING
16A
3
Tightening torques m alternator bolts mounting 2.1 daNm 2.1 daNm
power assisted steering pump mounting bolts
REMOVAL
Remove the accessories belt (see 11A, Top and front of engine, Accessories belt).
109225
109235
Remove: - power assisted steering pump mounting bolt (1), - power assisted steering pump mounting bolts (2) by pulling them through the holes in the pulley, - the power assisted steering pump from the multifunction support (without opening the circuit).
16A-4

K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING
16A
109217
Disconnect lead (4) from the alternator. Disconnect the connector (5). Remove: - alternator mounting bolts (3), - the alternator.
REFITTING
WARNING When replacing the belt, be sure to replace the tension wheels and idler pulleys. Refit the alternator. Tighten to torque the alternator mounting bolts (2.1 daNm). Proceed in the reverse order to removal. Torque tighten the power assisted steering pump mounting bolts (2.1 daNm). Remove the accessories belt (see 11A, Top and front of engine, Accessories belt).
16A-5

K7M, and 710, and DIRECTION ASSISTEE, and BASIC HEATING
16A
3
power assisted steering pump mounting bolts
REMOVAL
Remove the accessories belt (see 11A, Top and front of engine, Accessories belt).
109225
109235
Remove: - power assisted steering pump mounting bolt (1), - power assisted steering pump mounting bolts (2) by pulling them through the holes in the pulley, - the power assisted steering pump from the multifunction support (without opening the circuit).
16A-6

K7M, and 710, and DIRECTION ASSISTEE, and BASIC HEATING
16A
109217
Remove lead (4) from the alternator. Disconnect connector (5). Remove: - alternator mounting bolts (3), - the alternator.
REFITTING
WARNING When replacing the belt, be sure to replace the tension wheels and idler pulleys. Refit the alternator. Tighten to torque the alternator mounting bolts (2.1 daNm). Proceed in the reverse order to removal. Torque tighten the power assisted steering pump mounting bolts (2.1 daNm). Remove the accessories belt (see 11A, Top and front of engine, Accessories belt).
16A-7

K7J, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING
16A
Tightening torques m alternator bolts mounting 2.1 daNm 2.1 daNm 2.1 daNm
air conditioning compressor mounting bolts power assisted steering pump mounting bolts
REMOVAL
Remove: - the front bumper (see 55A, Exterior protection, Front bumper), - the accessories belt (see 11A, Top and front of engine, Accessories belt).
2
109397
108930
Disconnect power steering assistance connector (1 ). Remove: - power assisted steering mounting bolt (2), - power assisted steering pump mounting bolts (3) by pulling them through the holes in the pulley, - the power assisted steering pump from the multifunction support (without opening the circuit). Place the power assisted steering pump to one side.
16A-8

K7J, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING - the alternator.
16A
REFITTING
4
WARNING When replacing the belt, be sure to replace the tension wheels and idler pulleys. Refit the alternator.
Tighten to torque the alternator mounting bolts (2.1 daNm). Proceed in the reverse order to removal. Torque tighten:
109217
Remove lead (5) from the alternator. Disconnect the connector (4).
- the air conditioning compressor mounting bolts (2.1 daNm), - the power assisted steering pump mounting bolts (2.1 daNm), Refit: - the accessories belt (see 11A, Top and front of engine, Accessories belt),
- the front bumper (see 55A, Exterior protection, Front bumper).
109222
Remove: - the air conditioning compressor mounting bolts , - the air conditioning compressor from the multifunction support (without opening the circuit). Place the air conditioning compressor on the subframe. Remove: - the alternator mounting bolts (6),
16A-9

K7M, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING
16A
air conditioning compressor mounting bolts power assisted steering pump mounting bolts
1
2.1 daNm
REMOVAL
Remove: - the front bumper (see 55A, Exterior protection, Front bumper), - the accessories belt (see 11A, Top and front of engine, Accessories belt).
109397
108930
Disconnect power assisted steering pressostat connector (1 ). Remove: - power assisted steering pump mounting bolt (2), - power assisted steering pump mounting bolts (3) by pulling them through the holes in the pulley, - the power assisted steering pump from the multifunction support (without opening the circuit). Place the power assisted steering pump to one side.
16A-10

K7M, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING - the alternator.
16A
REFITTING
4
WARNING When replacing the belt, be sure to replace the tension wheels and idler pulleys. Refit the alternator.
Tighten to torque the alternator mounting bolts (2.1 daNm). Proceed in the reverse order to removal. Torque tighten:
109217
Remove lead (5) from the alternator. Disconnect the connector (4).
- the air conditioning compressor mounting bolts (2.1 daNm), - the power assisted steering pump mounting bolts (2.1 daNm), Refit: - the accessories belt (see 11A, Top and front of engine, Accessories belt),
- the front bumper (see 55A, Exterior protection, Front bumper).
109222
Remove: - the air conditioning compressor mounting bolts , - the air conditioning compressor from the multifunction support (without opening the circuit). Place the air conditioning compressor on the subframe. Remove: - the alternator mounting bolts (6),
16A-11
STARTING - LOAD Starter: Identification

K7J or K7M, and 710
16A
Engine K7J K7M
Starter MITSUBISHI M000T45171ZT
16A-12
STARTING - LOAD Starter motor

K7J, and 710
16A
2
Tightening torques m starter mounting bolts 4.4 daNm
REMOVAL
Mount the vehicle on a lift. Disconnect the battery, starting with the negative terminal.
109214
Remove gearbox control linkage mounting bolt (2).
WARNING The linkage is tted with a spacer; do not lose the spacer when removing bolt ( 2).
107847
Remove: - the computer cover by unclipping it in the direction of ( 1), - the expansion bottle mounting bolts, - the expansion bottle (without opening the circuit), Place the expansion bottle to one side.
16A-13

K7J, and 710
16A
4
3
107486 109215
Remove: - the starter motor mounting bolts (4), - the starter.
REFITTING
Tighten to torque the starter mounting bolts (4.4 daNm) . Proceed in the reverse order to removal. WARNING
109220
Remove: - bracket (3 ) mounting the inlet manifold to the cylinder block, - the starter motor wires.
Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery, Battery: Remove and ret .
16A-14

K7M, and 710
16A
2
Tightening torques m starter mounting bolts 4.4 daNm
REMOVAL
Mount the vehicle on a lift. Disconnect the battery, starting with the negative terminal.
109214
Remove gearbox control linkage mounting bolt (2). WARNING
The linkage is tted with a spacer; do not lose the spacer when removing bolt ( 2).
107847
Remove: - the computer cover by unclipping it in the direction of ( 1), - the expansion bottle mounting bolts, - the expansion bottle (without opening the circuit), Place the expansion bottle to one side.
16A-15

K7M, and 710
16A
4
3
107486 109215
Remove: - the starter motor mounting bolts (4), - the starter.
REFITTING
Tighten to torque the starter mounting bolts (4.4 daNm) . Proceed in the reverse order to removal. WARNING
109220
Remove: - bracket (3 ) mounting the inlet manifold to the cylinder block, - the starter motor leads.
Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery, Battery: Remove and ret .
16A-16
IGNITION coils
K7J, and 710
17A
Tightening torques m ignition coil unit mounting bolts 1.5 daNm
REMOVAL
107358
Disconnect: - the spark plug leads, - ignition coil unit connector (1 ). Remove: - the ignition coil unit mounting bolts, - the ignition coil unit.
17A-1
IGNITION coils
K7J, and 710
17A
REFITTING
106640
When refitting coils or spark plug leads, it is essential to apply a bead of GRAISSE FLUOREE (part number 82 00 168 855) with a diameter of 2 mm around the inner edge of the high voltage caps. Proceed in the reverse order to removal. WARNING Any damaged spark plug leads must be replaced. Torque tighten the ignition coil unit mounting bolts (1.5 daNm).
17A-2
IGNITION coils
K7M, and 710
17A
Tightening torques m ignition coil unit mounting bolts 1.5 daNm
REMOVAL
107358
Disconnect: - the spark plug leads, - ignition coil unit connector (1 ). Remove: - the ignition coil unit mounting bolts, - the ignition coil unit.
17A-3
IGNITION coils
K7M, and 710
17A
REFITTING
106640
When refitting coils or spark plug leads, it is essential to apply a bead of GRAISSE FLUOREE (part number 82 00 168 855) with a diameter of 2 mm around the inner edge of the high voltage caps. Proceed in the reverse order to removal. WARNING Any damaged spark plug leads must be replaced. Torque tighten the ignition coil unit mounting bolts (1.5 daNm).
17A-4
IGNITION Spark plugs

K7J or K7M, and 710
17A
- the spark plugs using tool (Ele. 1382). Engines K7M SAGEM CHAMPION K7J SAGEM RFN58LZ Flat skirt with seal Gap: 0.95 0.05 mm RFN58LZ RYCLC87 Brand CHAMPION Type RYCLC87
107358
Tightening: spark plugs (2.5 to 3 daNm)
Remove: - the spark plug leads,
106640
When refitting coils or spark plug leads, it is essential to apply a bead of FLUORINE GREASE (part number 82 00 168 855) with a diameter of 2 mm around the inner edge of the high voltage covers.
17A-5
PETROL INJECTION Location of components

K7J, and 710
17B
3 2 5 1 6 4
10
8 9
7
108559
( 1) ( 2) ( 3) ( 4) ( 5) ( 6) ( 7) ( 8) ( 9) ( 10)
Ignition coil unit Air lter Throttle valve Air temperature sensor Air pressure sensor Injection computer Oil pressure sensor Upstream oxygen sensor Coolant temperature sensor Engine position and speed sensor
108562
12 11
(6)
Injection computer
17B-1

K7J, and 710 ( 11) ( 12) Fuel pump relay Injection locking relay
17B
9
14 13 7 10 15
109211
(8)
107357
Upstream oxygen sensor Oil pressure sensor Coolant temperature sensor Engine position and speed sensor
(7) (9) (10 )
( 14) ( 13) ( 15)
Throttle position potentiometer Idle speed regulator Injectors
8 4 5
107356 108426
17B-2

K7J, and 710
17B
( 5) ( 4)
Air pressure sensor Air temperature sensor
DIRECTION ASSISTEE
17
1
107358
( 1)
Ignition coil unit
109397
(17 )
Power assisted steering pressure switch
AIR CONDITIONING
16
109219
18
( 16) Pinking sensor
108107
(18 )
Air conditioning pressostat
17B-3

K7M, and 710
17B
3 2 1 5 6 10 4
8 9
7
108559
( 1) ( 2) ( 3) ( 4) ( 5) ( 6) ( 7) ( 8) ( 9) ( 10)
Ignition coil unit Air lter Throttle valve Air temperature sensor Air pressure sensor Injection computer Oil pressure sensor Upstream oxygen sensor Coolant temperature sensor Engine position and speed sensor
108562
12 6 11
(6)
Injection computer
17B-4

K7M, and 710 ( 11) ( 12) Fuel pump relay Injection locking relay
17B
9
14 13 7 10
15
109211
(8)
107357
Upstream oxygen sensor Oil pressure sensor Coolant temperature sensor Engine position and speed sensor
(7) (9) (10 )
( 14) ( 13) ( 15)
Throttle position potentiometer Idle speed regulator Injectors
8 4 5
107356 108426
17B-5

K7M, and 710
17B
( 5) ( 4)
Air pressure sensor Air temperature sensor
DIRECTION ASSISTEE
17
1
107358
( 1)
Ignition coil unit
109397
(17 )
Power assisted steering pressure switch
AIR CONDITIONING
16
109219
18
( 16) Pinking sensor
108107
(18 )
Air conditioning pressostat
17B-6
PETROL INJECTION Oxygen sensors

K7M, and 710 Essential special tooling Mot. 1495 22 mm oxygen sensor removal / retting socket - 1/2" square drive and a 24 mm Allen key
17B
REMOVAL
I -UPSTREAM OXYGEN SENSOR
Tightening torques m oxygen sensors heat shield mounting nuts 4.5 daNm 2.5 daNm
108426
107925
Remove: - the exhaust manifold heat shield, - the upstream oxygen sensor connector from its support by sliding it (in the direction of the arrow). Disconnect the upstream oxygen sensor connector. Remove oxygen sensor using the tool (Mot. 1495).
17B-7

K7M, and 710 II - DOWNSTREAM OXYGEN SENSOR
17B
108424
Mount the vehicle on a lift. Remove the downstream oxygen sensor connector from its support by sliding it (in the direction of the arrow). Disconnect the connector of the downstream lambda sensor. Remove the lambda sensor.
REFITTING
Proceed in the reverse order to removal. Torque tighten: - the oxygen sensors (4.5 daNm) using the tool (Mot. 1495), - the heat shield mounting nuts (2.5 daNm).
17B-8

K7J, and 710 Essential special tooling Mot. 1495 22 mm oxygen sensor removal / retting socket - 1/2" square drive and a 24 mm Allen key
17B
REMOVAL
I -UPSTREAM OXYGEN SENSOR
Tightening torques m oxygen sensors heat shield mounting nuts 4.5 daNm 2.5 daNm
108426
107925
Remove: - the exhaust manifold heat shield, - the upstream oxygen sensor connector from its support by sliding it (in the direction of the arrow). Disconnect the upstream oxygen sensor connector. Remove oxygen sensor using the tool (Mot. 1495).
17B-9

K7J, and 710 II - DOWNSTREAM OXYGEN SENSOR
17B
108424
Mount the vehicle on a lift. Remove the downstream oxygen sensor connector from its support by sliding it (in the direction of the arrow). Disconnect the connector of the downstream lambda sensor. Remove the lambda sensor.
REFITTING
Proceed in the reverse order to removal. Torque tighten: - the oxygen sensors (4.5 daNm) using the tool (Mot. 1495), - the heat shield mounting nuts (2.5 daNm).
17B-10
PETROL INJECTION Position and speed sensor

K7J, and 710
17B
Essential equipment diagnostic tool
109211
Program with the engine flywheel target after replacing the speed and position sensor (1) or the engine flywheel: - make a deceleration with injection cut-off in second, third, fourth or fifth gear between 3,500 and 3,000 rpm , for at least 2 seconds, - make a second deceleration with injection cut-off in second, third, fourth or fifth gear between 2,400 and 2,000 rpm for at least 3 seconds. Using the diagnostic tool, check that this programming is properly done, ET060: Flywheel signal with engine running . Read the fault codes. Repair if necessary. Clear the fault codes. Check that the vehicle is working correctly.
17B-11
PETROL INJECTION Position and speed sensor

K7M, and 710
17B
109211
Program with the engine flywheel target after replacing the speed and position sensor (1) or the engine flywheel: - make a deceleration with injection cut-off in second, third, fourth or fifth gear between 3,500 and 3,000 rpm , for at least 2 seconds, - make a second deceleration with injection cut-off in second, third, fourth or fifth gear between 2,400 and 2,000 rpm for at least 3 seconds. Using the diagnostic tool, check that this programming is properly done, ET060: Flywheel signal with engine running . Read the fault codes. Repair if necessary. Clear the fault codes. Check that the vehicle is working correctly.
17B-12
PETROL INJECTION Fuel supply computer

K7J, and 710
17B
Tightening torques m computer mounting nuts computer protector mounting bolts battery mounting clamp bolts 0.8 daNm 0.8 daNm 1.2 daNm
REMOVAL
108564
Remove: - the computer protector mounting bolts, - the computer protector.
1
107847
Disconnect the battery starting with the negative terminal. Remove: - the mounting (1 ) bolt of the battery, - the battery, - the computer cover by unclipping the (2).
17B-13

K7J, and 710
17B
REFITTING
Proceed in the reverse order to removal. Torque tighten: - the computer mounting nuts (0.8 daNm), - the computer protector mounting bolts (0.8 daNm), - the battery mounting clamp bolts (1.2 daNm). WARNING
Connect the battery, starting with the positive terminal; carry out thenecessary programming (see 80A, Battery, Battery: Remove and Ret). WHEN REPLACING THE COMPUTER
108562
WARNING The computer delivered as a spare part is already programmed. The computer can be reprogrammed with the diagnostic tool but any computer reprogramming is prohibited.
4
After replacing the computer: - Switch off the ignition. - Initialise the computer: start the engine, switch the engine off, wait 30 seconds. - Switch on the ignition again and carry out the following stages using the diagnostic tool: use command VP001 Write VIN , perform a road test then check with the diagnostic tool.
108563
Remove the mounting bolts (3) of the computer. Disconnect the computer by pulling in (4). Remove the computer.
17B-14

K7J, and 710 1 - Immobiliser code The computers are supplied uncoded. When a computer is replaced it must be programmed with the vehicle code, and checked to ensure that the immobiliser function is working properly. Switch on the ignition for a few seconds then switch it off. WARNING - The injection computer retains the immobiliser code for life. - The system has no security code. - Running tests with computers borrowed from the Parts Department or from another vehicle which must then be returned is prohibited. These computers are permanently coded. Check the condition of the computer (coded or not coded) using the diagnostic tool: - if the state ET099 Immobiliser code programmed is inactive, this means that the injection computer is not coded. - if the state ET002 Immobiliser is active, starting the engine is impossible. 2 - Programming Perform flywheel target programming during a road test: - a deceleration with injection cut-off in second, third, fourth or fifth gear between 3,500 and 3,000 rpm, for at least 2 seconds, - make a second deceleration with injection cut-off in second, third, fourth or fifth gear between 2,400 and 2,000 rpm for at least 3 seconds. Using the diagnostic tool, check that this programming is properly done, ET060 Flywheel signal with engine running . Read the fault codes. Repair if necessary. Clear the fault codes.
17B
17B-15

K7M, and 710
17B
Tightening torques m computer mounting nuts computer protector mounting bolts battery mounting clamp bolts 0.8 daNm 0.8 daNm 1.2 daNm
REMOVAL
108564
Remove: - the computer protector mounting bolts, - the computer protector.
1
107847
Disconnect the battery starting with the negative terminal. Remove: - the mounting (1 ) bolt of the battery, - the battery, - the computer cover by unclipping the (2).
17B-16

K7M, and 710
17B
REFITTING
Proceed in the reverse order to removal. Torque tighten: - the computer mounting nuts (0.8 daNm), - the computer protector mounting bolts (0.8 daNm), - the battery mounting clamp bolts (1.2 daNm). WARNING
Connect the battery, starting with the positive terminal; carry out thenecessary programming (see 80A, Battery, Battery: Remove and Ret). WHEN REPLACING THE COMPUTER
108562
WARNING The computer delivered as a spare part is already programmed. The computer can be reprogrammed with the diagnostic tool but any computer reprogramming is prohibited.
4
After replacing the computer: - Switch off the ignition. - Initialise the computer: start the engine, switch the engine off, wait 30 seconds. - Switch on the ignition again and carry out the following stages using the diagnostic tool: use command VP001 Write VIN , perform a road test then check with the diagnostic tool.
108563
Remove the mounting bolts (3) of the computer. Disconnect the computer by pulling in (4). Remove the computer.
17B-17

K7M, and 710 1 - Immobiliser code The computers are supplied uncoded. When a computer is replaced it must be programmed with the vehicle code, and checked to ensure that the immobiliser function is working properly. Switch on the ignition for a few seconds then switch it off. WARNING - The injection computer retains the immobiliser code for life. - The system has no security code. - Running tests with computers borrowed from the Parts Department or from another vehicle which must then be returned is prohibited. These computers are permanently coded. Check the condition of the computer (coded or not coded) using the diagnostic tool: - if the state ET099 Immobiliser code programmed is inactive, this means that the injection computer is not coded. - if state ET002 Immobiliser is active, starting the engine is impossible. 2 - Programming Perform flywheel target programming during a road test: - a deceleration with injection cut-off in second, third, fourth or fifth gear between 3,500 and 3,000 rpm, for at least 2 seconds, - make a second deceleration with injection cut-off in second, third, fourth or fifth gear between 2,400 and 2,000 rpm for at least 3 seconds. Using the diagnostic tool, check that this programming is properly done, ET060 Flywheel signal with engine running . Read the fault codes. Repair if necessary. Clear the fault codes.
17B
17B-18
PETROL INJECTION Computer: Connection

K7J, and 710
17B
76 75 90
61
31
60 30 16 15
109395
To connect the injection computer (see wiring diagram suited to the vehicle subject to fault finding, component 120).
17B-19
PETROL INJECTION Computer: Connection

K7M, and 710
17B
76 75 90
61 31
60 30 16 15
109395
To connect the injection computer (see wiring diagram suited to the vehicle subject to fault finding, component 120).
17B-20
PETROL INJECTION Special notes

L90, and K7J, and 710 SPECIAL NOTES FOR MULTIPOINT INJECTION 90-TRACK EMS 31-32 computer controlling injection and ignition. Use of the diagnostic tool. Multipoint injection operating in sequential mode without a cylinder marking sensor or camshaft position sensor. This means that phasing is carried out by software using the TDC sensor. Idle speed corrected according to: - air conditioning, - electrical consumers in operation. Fuel vapour absorber bleed solenoid valve controlled by the opening cyclic ratio (OCR) according to engine speed and operating conditions. Use (on some models) of two oxygen sensors positioned upstream and downstream of the catalytic converter. Automatic configuration in air conditioning operating mode by exchange of signals between the computers. Deconfiguration is impossible (even using the diagnostic tool ).
17B
17B-21
PETROL INJECTION Special notes

K7M, and 710 SPECIAL NOTES FOR MULTIPOINT INJECTION 90-TRACK EMS 31-32 computer controlling injection and ignition. Use of the diagnostic tool. Multipoint injection operating in sequential mode without a cylinder marking sensor or camshaft position sensor. This means that phasing is carried out by software using the TDC sensor. Idle speed corrected according to: - air conditioning, - electrical consumers in operation. Fuel vapour absorber bleed solenoid valve controlled by the opening cyclic ratio (OCR) according to engine speed and operating conditions. Use (on some models) of two oxygen sensors positioned upstream and downstream of the catalytic converter. Automatic configuration in air conditioning operating mode by exchange of signals between the computers. Deconfiguration is impossible (even using the diagnostic tool ).
17B
17B-22
PETROL INJECTION Injection warning light

K7J or K7M, and 710 PRINCIPLE FOR INJECTION WARNING LIGHT ON THE INSTRUMENT PANEL LIGHTING UP 1 - Vehicle not equipped with the engine immobiliser function The warning light is lit for approximately 3 seconds then goes out. 2 - Vehicles with engine immobiliser function deactivated When switching on the ignition, the injection warning light is continuously lit for 3 seconds then goes out. When the doors are unlocked, the red immobiliser warning light, which was previously flashing, extinguishes. When switching on the ignition, it is continuously lit for 3 seconds then goes out. 3 - Vehicles with engine immobiliser function activated When switching on the ignition, the computer does not recognise the code and stops the engine from starting. The injection warning light is lit 3 seconds then goes out. Before switching on the ignition, the red immobiliser warning light flashes. When switching on the ignition, it flashes more rapidly. If a fault is detected in the engine immobiliser system whilst the engine is running, the injection warning light flashes in the engine speed range between idle speed and 1500 rpm. 4 - Fault in a component of the injection system The warning light comes on if a fault has been detected in: - the inlet pressure sensor, - the throttle potentiometer or throttle valve, - the idle speed regulator.
17B
17B-23
PETROL INJECTION Immobiliser function

L90, and K7J, and 710 L90, and K7M, and 710
17B
Essential equipment diagnostic tool These vehicles are equipped with second-generation engine immobiliser systems. The injection computers must be programmed with the immobiliser code for them to work. I -REPLACING AN INJECTION COMPUTER The computers are supplied uncoded. When a computer is replaced it must be programmed with the vehicle code, then checked to ensure that the immobiliser function is working properly. To do this, switch on the ignition for a few seconds without starting the engine and then switch it off. WARNING - The injection computer retains the immobiliser code for life. - The system has no security code. - It is forbidden to perform tests with computers borrowed from the Parts Department or from another car which must then be returned. These computers are permanently coded. II - CHECKING THE STATUS OF THE COMPUTER (CODED OR UNCODED) Using the diagnostic tool, it is possible to check the status of the injection computer. - Connect the diagnostic tool to the diagnostic socket. - Select and confirm the vehicle type. - Select and confirm petrol injection . - Choose the status option: if status E T 0 9 9 immobiliser code programmed is inactive, this indicates that the injection computer has not been coded, if status ET002 engine immobiliser is active, it is impossible to start the engine.
17B-24
PETROL INJECTION Injection - air conditioning programming

L90, and K7J, and 710 L90, and K7M, and 710 I -SYSTEM OPERATION The air conditioning system is a cold loop which operates the following components: - a control panel, - an injection computer, - a compressor. It is not adjusted, i.e. the volume of cold air is constant from the moment the compressor begins to operate. Pressing the AC button on the passenger compartment control panel produces either status 0 (request for cold air deactivated) or 1 (request for cold air activated). This status signal is transmitted via a wire connection to the injection computer, which then authorises the request for cold air if necessary. II - COMPRESSOR OPERATION PROGRAMMING During certain operating phases, the injection computer disables the operation of the compressor. Injection computer programming: - If the engine speed is too low: operation of the compressor is not authorised. - If the load exerted on the engine is too great (rapid acceleration, driving up a steep incline or vehicle heavily laden): operation of the compressor is not authorised. - If the refrigerant fluid is already pressurised in the compressor: the computer enters safety lock-up mode and operation of the compressor is not authorised. If the injection computer authorises operation of the compressor, status 1 is transmitted at the level of power required to supply the compressor actuator.
17B
17B-25
PETROL INJECTION Throttle body potentiometer

K7J or K7M, and 710
17B
3
REMOVAL
1
108423
Remove air filter unit mounting bolts (1).
107356
Unclip ball joint ( 3).
4 2 5
107361
107357
Disconnect: - potentiometer connector (4), - the idling speed stepper motor connector (5). Remove: - the throttle valve by tilting it, - potentiometer mounting bolts (4 ), - the potentiometer.
17B-26
PETROL INJECTION Throttle body potentiometer

K7J or K7M, and 710
17B
REFITTING
17B-27
PETROL INJECTION Idle speed correction

L90, and K7J, and 710 L90, and K7M, and 710 I -POWER ASSISTED STEERING PRESSOSTAT/ INJECTION COMPUTER CONNECTION (IF THE VEHICLE IS EQUIPPED WITH POWER ASSISTED STEERING) The injection computer receives a signal from the power assisted steering pressostat (can be seen on the diagnostic tool). This depends on the pressure in the hydraulic circuit and on the fluidity of the power assisted steering fluid. The higher the pressure, the more energy is used by the power steering pump. The idle speed can be approximately 100 rpm faster on some versions. II - ELCTRICAL CORRECTION ACCORDING TO BATTERY VOLTAGE AND ELECTRIC POWER BALANCE The purpose of this correction is to compensate for the drop in voltage due to a power consumer being switched on when the battery is not sufficiently charged. To do this, the idle speed is increased, allowing the rotation of the alternator to be increased and, consequently, the battery voltage. The lower the voltage, the greater the correction. Correction of the engine speed is therefore variable. It begins when the voltage drops below 12.8 V. Correction begins at the nominal engine idle speed and may increase by no more than an additional 150 rpm .
17B
17B-28
PETROL INJECTION Richness regulation

L90, and K7J, and 710 L90, and K7M, and 710 I -SENSOR HEATING The sensors are heated by the computer: - when the engine is started for the upstream sensor, - after the engine has been running for a certain length of time, mapped according to the top dead centre and the coolant temperature outside the no load position for the downstream sensor. The lambda sensors are heated constantly until the engine is switched off. II - UPSTREAM SENSOR VOLTAGE Reading on the fault finding tool: parameter "PR009: UPSTREAM OXYGEN SENSOR VOLTAGE": the value read represents the voltage supplied to the computer by the lambda sensor located upstream of the catalytic converter. It is expressed in mV. When the engine is operating in a closed loop, the voltage must vary rapidly between two values: - 20 mV 50 for a lean mixture, - 840 mV 70 for a rich mixture. The smaller the difference is between the minimum and maximum values, the poorer the signal is from the sensor (this difference is usually 500 mV). III - DOWNSTREAM SENSOR VOLTAGE Reading on the fault finding tool: parameter PR010: DOWNSTREAM LAMBDA SENSOR VOLTAGE: the value read represents the voltage supplied to the computer by the lambda sensor located downstream from the catalytic converter. It is expressed in mV. The function of this sensor is to run diagnostics on the catalytic converter and to perform a second, more precise, check on the richness (slow regulation loop). This function only starts operating after the engine has been running at normal operating temperature for a while and does not operate at idle speed. When the engine is operating in a closed loop, at stabilised speed, the voltage should vary within the range 600 mV 100. When decelerating, the voltage should be less than 200 mV. The voltage read on the control unit at idling speed should be ignored. IV - RICHNESS CORRECTION The value read on the fault finding tool for parameter " PR035: RICHNESS CORRECTION VALUE" represents the average of the richness corrections applied by the computer depending on the richness of the fuel mixture as determined by the oxygen sensor located
17B
upstream of the catalytic converter (the oxygen sensor in fact analyses the oxygen content of the exhaust fumes. The correction value has an average of 128 and for limits 0 and 255 : - value less than 128: leaner mixture required, - value greater than 128: richer mixture required. V - ENTRY INTO RICHNESS REGULATION MODE Entering the regulation phase takes effect after a timed starting period if the coolant temperature is more than 22 C and according to a timed period of 28 s after starting the engine. When the richness regulation phase has not yet been entered, the value displayed is 128. Non-loop mode When richness regulation is occurring, the operating phases when the computer ignores the voltage information from the oxygen sensor are: - at full load: variable and greater than 128, - in strong acceleration: variable and greater than 128, - in deceleration with the no load signal (injection cutout): 128, - in the event of an oxygen sensor fault: 128. VI - DEFECT MODE IN THE EVENT OF AN OXYGEN SENSOR FAULT When the voltage delivered by the lambda sensor is incorrect (varying very little or not at all) in richness regulation, the computer goes into defect mode (value = 128 ) if the fault has been recognised as present for 10 seconds . Only in that case will the fault be memorised. If an oxygen sensor fault is present and recognised and if the fault has already been stored, the system enters the open loop mode directly. In this case, the PR035 "Richness correction value" parameter adopts the value 128.
17B-29
PETROL INJECTION Central coolant temperature management

K7J or K7M, and 710
17B
The fan assembly is activated at high speed if the coolant temperature exceeds 102C or if the low speed is defective and is stopped when the temperature falls below 100C. The fan assembly may be controlled at low speed for the antipercolation device and at high speed for the air conditioning system. If the low speed facility is faulty, the fan will run at high speed under the low speed conditions.
107356
The system is fitted with a single coolant temperature sensor used for: - the injection system, - running the fan assembly, - the temperature warning light on the instrument panel. Coolant temperature sensor (1 ) has 3 tracks: - two tracks for injection computer coolant temperature signal, - one track to indicate the coolant temperature on the instrument panel. OPERATION The coolant temperature sensor (1) enables: - the coolant temperature to be indicated on the instrument panel, - the computer to be informed about the engine coolant temperature. The injection computer manages the following according to the coolant temperature: - the injection system, - the fan assembly relay, - the coolant temperature warning light. The warning light is controlled by the injection computer if the coolant temperature exceeds 120C. The fan assembly is activated at low speed if the coolant temperature exceeds 100C or in the event of coolant temperature sensor failure and is stopped when the temperature falls below 96C.
17B-30
PETROL INJECTION Special notes on the system (when driving)

L90, and K7J, and 710 L90, and K7M, and 710 FOR VEHICLES FITTED WITH O.B.D: How the O.B.D. fault finding system works: when a fault causing excessive pollution is detected, an instrument panel warning light comes on (O.B.D warning light), and tells the driver that he needs to have his vehicle repaired. The fault finding strategies dealt with by the On Board Diagnostic system are: - electrical fault finding, - misfire fault finding, - upstream oxygen sensor operational fault finding, - catalytic converter fault finding. Electrical fault finding and misfire fault finding are carried out continuously. Upstream oxygen sensor operational fault finding and catalytic converter fault finding are carried out only once while the vehicle is being driven, provided that the necessary fault finding conditions are met: - air/coolant temperature conditions, - speed condition (range of values), - engine conditions (manifold pressure, speed, range of values and stability), - delay since start. The OBD management program supplements the management of conventional electrical breakdowns. To meet this standard the requirements are: - lighting up of the OBD warning light (or, for some faults, causing to it flash), - storing OBD faults. IMPLICATIONS FOR FAULT FINDING AND REPAIRS Special care is required when working on the vehicle to prevent the O.B.D. warning light from switching on after the vehicle has been returned to the customer. Some faults only appear while driving, when the adaptives have been programmed. Confirmation of the repair is therefore essential. Note:
17B
All electrical faults which result in exceeding the pollution limit cause the On Board Diagnostic warning light to come on.
WARNING At the end of each test, it is essential that the ignition is not switched off before the result is read on the diagnostic tool. Switching off the ignition will lead to the results being misinterpreted.
17B-31
PETROL INJECTION
Conditions for carrying out fault finding (when driving)
L90, and K7J, and 710 L90, and K7M, and 710 FOR VEHICLES FITTED WITH O.B.D: I -FAULT FINDING CONDITIONS If, when the ignition if switched on and the engine stopped, the air temperature detected by the temperature sensor is not within - 6 C to 119 C , or if the water temperature detected by the sensor is not within - 6 C to 119 C, or if the atmospheric pressure is less than 775 mbar (altitude of about 2,500 m), then O.B.D. fault finding is not authorised until the next time the ignition is switched on. For the On Board Diagnostic system to function correctly, there must be no electrical faults in the injection system, even if the OBD warning light does not come on. Catalytic converter and oxygen sensor fault finding can only be carried out consecutively. When the catalytic converter or oxygen sensor fault finding procedures are in progress, the canister bleed is closed and the richness adaptives are locked at their last value. II - TEST PROCEDURE - Rectify the electrical faults. - Erase all faults. - Carry out all injection programming (if necessary). III - COMPLETE O.B.D. INITIALISATION BY COMMAND MODE - Clearing the fault memory. - Erasing programming (for work on a component which could have disturbed the programming: idle speed regulation valve, flywheel target, etc.) IV - PROGRAMMING REQUIRED FOR OBD FAULT FINDING 1 - Torque Gas Programming (State: ET014 cylinder 1 recognition = DONE, engine running) This is programmed by: - a deceleration with injection cut-off in second, third, fourth or fifth gear between 3,000 and 3,000 rpm for at least 2 seconds, - a second deceleration with injection cut-off in second, third, fourth or fifth gear between 2,400 and 2,000 rpm for at least 3 seconds.
17B
2 - Programming of richness adaptive parameters To carry out this programming, run the vehicle by respecting the pressure ranges laid down in section: "Injection: Adaptive richness correction". State ET202: OBD fault finding, misfirings included, should be ACTIVE .
17B-32
PETROL INJECTION Combustion misfire fault finding

L90, and K7J, and 710 L90, and K7M, and 710 FOR VEHICLES FITTED WITH O.B.D: The diagnostic can detect, for example: - a dirty spark plug, - clogging of the injectors or an injector flow fault, - a fault in the supply system (pressure regulator, fuel pump, etc.), - faulty wiring of the petrol and injection circuits (coil secondary, etc), Fault finding is performed by measuring the instantaneous variations in engine rotation speed. Observation of a drop in torque detects combustion misfires. This fault finding is practically continuous while the car is being driven. If it is not carried out, or if a fault is detected, all other On Board Diagnostic fault finding This fault finding procedure makes it possible to diagnose two types of fault: - destructive misfires resulting in destruction of the catalytic converter. These cause the OBD warning light to light up immediately and flash. - Polluting combustion misfirings cause the O.B.D. pollution threshold to be exceeded. These cause the OBD warning light to illuminate if they are detected during three consecutive journeys. I -DETECTION CONDITIONS Before starting, check that programming has been performed. The conditions prior to switching on the ignition and the current conditions must also be satisfied. Make sure status: - ET014 Cylinder 1 recognition : DONE , - ET202 OBD fault finding, misfiring included : ACTIVE . Detection is carried out as soon as the coolant temperature is above 7 5 C, in three operating ranges between idle speed and 4,500 rpm. The test can now be performed by keeping the engine at idle speed for 11 minutes. II - CONFIRMATION OF REPAIR Make sure statuses:
17B
- ET014 Cylinder 1 recognition : DONE , - ET202 OBD fault finding, misfiring included : ACTIVE . No fault detected and the On Board Diagnostic warning light is out.
WARNING At the end of each test, it is essential that the ignition is not switched off before the result is read on the fault nding tool. Switching off the ignition will lead to the results being misinterpreted. If after the test, the diagnostic tool has detected misfirings (see Workshop Repair Manual 390, 17B, Petrol injection, Summary of faults).
17B-33
PETROL INJECTION Catalytic converter fault finding

L90, and K7J, and 710 L90, and K7M, and 710 FOR VEHICLES FITTED WITH O.B.D: The purpose of catalytic converter fault finding is to detect a malfunction which would cause hydrocarbon pollutant emissions to exceed the On Board Diagnostic limit. The ability of the catalytic converter to store oxygen indicates its condition. As the catalytic converter ages, its ability to store oxygen reduces along with its ability to treat pollutant gases.
17B
I -CONDITIONS FOR ENTERING FAULT FINDING MODE Fault finding of the catalytic converter can only take place after the engine has been running for the time detailed in the following table, if all the conditions prior to switching on the ignition are satisfied and maintained: - no electrical faults, - cylinder recognition done, - no misfiring detected, - no catalytic converter fault finding performed since the ignition was switched on, - programming has been done, - main loop and double loop active, - coolant temperature above 75C.
Engine
Speed, (kph) 63 to 130 63 to 130
mph
Engine speed (rpm) 1,856 to 3,808 1,856 to 3,808
Manifold pressure (mbar) 400 to 750 380 to 650
Stabilisation time (seconds) 11 11
Time before authorisation (minutes) 17 17
K7M K7J
II - FAULT DETECTION Fault finding is performed over a stabilised range in fifth gear at 43 mph (70 km per hour). When the conditions for starting fault finding are met, richness excitation peaks are applied, which has the effect of sending bursts of oxygen into the catalytic converter. If the catalytic converter is in good condition it absorbs the oxygen and the downstream oxygen sensor value will remain at its average value. If it is in poor condition, it rejects the oxygen and the lambda sensor voltage oscillates. If the fault is confirmed on three consecutive occasions, the On Board Diagnostic warning light comes on. The test duration cannot exceed 52 seconds.
III - CONFIRMATION OF REPAIR - ET103 Catalytic ACTIVE , converter included :
- ET107 Catalytic converter done : ACTIVE , - no catalytic converter operating fault detected.
WARNING At the end of each test, it is essential that the ignition is not switched off before the result is read on the diagnostic tool. Switching off the ignition will lead to the results being misinterpreted. If after the test, the diagnostic tool has detected a functional fault of the catalytic converter, see fault finding procedure associated with this symptom.
17B-34
PETROL INJECTION Oxygen sensor fault finding

L90, and K7J, and 710 L90, and K7M, and 710 FOR VEHICLES FITTED WITH O.B.D: The purpose of oxygen sensor fault finding is to detect a fault which would cause the On Board Diagnostic limit to be exceeded by hydrocarbon pollutant emissions. It is performed by measuring and comparing oxygen sensor vibration periods. There are two types of possible faults on the oxygen sensors: - mechanical damage to an electrical component (breakage, cut in wire) which leads to an electrical fault, - chemical damage to the component which causes the response time of the sensor to slow down, thus increasing its switching period. When the required test conditions are met, the average of the sensor periods read is taken, subtracting the effects of interference, then compared with a period of the On Board Diagnostic limit. Engine Speed, (kph) 63 to 130 63 to 130 mph Engine speed (rpm) 1,856 to 3,808 1,856 to 3,808 Manifold pressure (mbar) 380 to 850 380 to 850 Stabilisation time (seconds) 8 8 I -TEST CONDITIONS
17B
Fault finding of the oxygen sensor can only take place after the engine has been running for a while and under specific operating conditions, detailed in the table below, and if all the conditions prior to the ignition being switched on are met and maintained: - no electrical faults detected, - programming and cylinder recognition done, - no oxygen sensor fault finding performed since the ignition was switched on, - water temperatureover 75C .
Time before autorisation (minutes) 14 14
K7M K7J
II - FAULT DETECTION
Fault finding is performed while the vehicle is being driven in one gear, travelling at a steady speed and for the minimum period of time specified in the following table: Engine K7J K7M Gearbox ratio 5 5 Speed, mph (kph) 70 70 Maximum period (s) 40 40
For this test, the computer inhibits petrol vapour canister bleeding. The computer gives the sensors fault finding included signal.
III - CONFIRMATION OF REPAIR - ET102: Sensor ACTIVE , fault finding included :
- ET106: Sensor fault finding done : ACTIVE , - no fault detected and the On Board Diagnostic warning light is out.
WARNING At the end of each test, it is essential that the ignition is not switched off before the result is read on the diagnostic tool. Switching off the ignition will lead to the results being misinterpreted. If after the test, the diagnostic tool has found a lambda sensor fault, (see Workshop Repair Manual 390 Fault finding, 17B, Petrol injection, Summary of faults).
17B-35
COOLING SYSTEM General information

Vehicles in the current range have cooling circuits with the following basic specifications: - hermetically-sealed pressurused circuit (expansion chamber valve), - circuit uses type D fluid, - passenger compartment heating system via a heater matrix radiator under the dashboard. GENERAL PRECAUTION
19A
IMPORTANT The circuits are designed to be pressurised, so be careful at high temperatures (risk of serious burns). Never remove the cap from the expansion bottle while the engine is hot. Similarly, take care when working under the bonnet, as the radiator fan may start up unexpectedly. Never use fluids other than the one specified: GLACEOL RX (type D). Never use coolants such as: - ready-to-use coolant, - anti-freeze (must be diluted; see directions on the container).
WARNING - The coolant helps to keep the engine running properly (heat exchange). - The system does not operate using pure water. When an operation requires the circuit to be completely drained, it is essential to flush the circuit using clean water, blow compressed air into it to remove as much water as possible, fill and bleed the circuit, then measure the effective protection of the circuit, i.e.: - protection down to - 25 C 2 C for cold and temperate countries, - protection down to - 40 C 2 C for very cold countries.
19A-1
COOLING SYSTEM Specifications

K7J or K7M, and 710 I -GRADE AND QUANTITY OF COOLANT
19A
Grade GLACEOL RX (TYPE D). Use coolant only.
Engine K7J 710
Quantity (litres) Approximately 5.45
K7M 710 Special notes: - Protection down to - 25C 2 for cold and temperate countries.
- Protection down to- 40C 2 for very cold countries. II - THERMOSTAT
Engine K7J 710 K7M 710
Start of opening (C) 89 89
End of opening (C) 99 2 99 2
All engines: The rating of the expansion bottle degassing valve with a yellow hand symbol is 1.4 bar.
19A-2
COOLING SYSTEM Checking

Essential special tooling Ms. 554-01 Plug (spare) to test expansion bottle valves Equipment for checking coolant circuit and expansion bottle valve Plug (spare) to test expansion bottle valves II - CHECKING THE VALVE
19A
WARNING The expansion bottle valve must be replaced if coolant is leaking from the valve. Fit the appropriate cap of tool (Ms. 554-06) onto the tester (Ms. 554-07). Screw the expansion bottle valve onto the cap of tool (Ms. 554-06). Use tool (Ms. 554-07) to check the valve rating. Note: - The required pressure is 1.4 bar 0.1, the valve rating. - The pressure should not drop; if it does, replace the valve.
Ms. 554-07
Ms. 554-06
I -CHECKING THE CIRCUIT SEALING
97871
Replace the expansion bottle valve through the cap of tool (Ms. 554-01). Connect the cooling circuit tester (Ms. 554-07) to the cap of tool (Ms. 554-01) . Warm the engine until the fan starts to operate, then stop the engine. Pressurise the circuit using tool (Ms. 554-07). Note: - The required pressure is 0.1 bar below the valve rating. - The pressure should not drop; if it does, look for the leak.
19A-3
COOLING SYSTEM Diagram

K7J, and 710
19A
5
1 4
3 7
109415
( 1) ( 2) ( 3) ( 4) ( 5) ( 6) ( 7)
Engine Water pump Thermostat Bleed screw Heater radiator Cooling radiator Expansion bottle
Note: The expansion bottle degassing valve rating is 1.4 bar.
19A-4
COOLING SYSTEM Diagram

K7M, and 710
19A
5
1 4
3 7 6
109415
( 1) ( 2) ( 3) ( 4) ( 5) ( 6) ( 7)
Engine Water pump Thermostat Bleed screw Heater radiator Cooling radiator Expansion bottle
Note: The expansion bottle degassing valve rating is 1.4 bar.
19A-5
COOLING SYSTEM Bleeding and filling the cooling circuit.

K7J, and 710 K7M, and 710 Essential special tooling Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Remote operation pliers for cooling system hose clips
19A
FILLING
Mot. 1448
WARNING The engine must be stopped and the air conditioning system must be switched off so that the engine cooling fan is not running when you start.
Before starting work, protect the electrical accessories using plastic bags.
WARNING - Drain the oil when the engine is warm. - Flush and rell with oil with the engine cold or warm. - Never ush a warm engine (risk of major thermal shock).
DRAINIG - FLUSHING
Mount the vehicle on a lift. Remove the engine undertray. Open: - the cooling system at the lower radiator hose, using tool (Mot. 1202-01) or (Mot. 1448), - the expansion chamber and the bleed screw in order to drain the circuit. Close the bleed screw again. Refit the bottom hose without the clip. Refill the circuit with tap water to flush it. Disconnect the lower hose. Open the bleed screw, Blow compressed air into the circuit through the expansion bottle valve aperture to remove as much water as possible. Refit the lower hose and its clip. Bleed screw ( 1) must be opened.
108561
Note: - Do not tighten the bleed screws. - Fluid circulates continuously in the heater radiator (the heater radiator contributes to engine cooling).
19A-6
COOLING SYSTEM Bleeding and filling the cooling circuit.

K7J, and 710 K7M, and 710 Fill the circuit through the expansion chamber. Close the bleed screw as soon as the fluid runs out in a continuous jet. Fill up the expansion bottle until the coolant overflows. Refit the expansion bottle valve. Bleed the cooling circuit. IMPORTANT - Do not open the bleed screw(s) while the engine is running or hot. - Never open the expansion bottle while the engine is hot (over 50C) or running. - Top up if necessary. - Retighten the expansion bottle cap while the engine is hot. - Using approved equipment, measure the degree of coolant protection. - Check for any leaks. - Make sure the passenger compartment heating is working properly. Start the engine. Run the engine at 2500 rpm until the cooling fan(s) has/have run three times (time required for automatic degassing). If necessary, top up the coolant level in the expansion chamber.
19A
19A-7
COOLING SYSTEM Bleeding the cooling circuit

AUTOMATIC BLEEDING
IMPORTANT - Do not open the bleed screw(s) while the engine is running or hot. - Never open the expansion bottle while the engine is hot (over 50C) or running. - Top up if necessary. - Retighten the expansion bottle cap while the engine is hot. - Using approved equipment, measure the degree of coolant protection. - Check for any leaks. - Make sure the passenger compartment heating is working properly. Start the engine. Run the engine at 2500 rpm until the cooling fan(s) has/have run three times (time required for automatic degassing). If necessary, top up the coolant level in the expansion chamber.
19A
19A-8
COOLING SYSTEM Cooling radiator

K7J or K7M, and 710, and AIR CONDITIONING Essential special tooling Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Remote operation pliers for cooling system hose clips
19A
Mot. 1448
REMOVAL
Mount the vehicle on a two-post lift. Remove the engine undertray. Drain the cooling circuit via the lower radiator hose using tool (Mot. 1202-01) or (Mot. 1448) (see 19A, Cooling, Draining - Filling the cooling circuit).
108630
Remove bolts ( 2).
108633
Remove bolts (1). Partially remove the front wheel arch liners.
108629
Remove bolts ( 3).
19A-9

K7J or K7M, and 710, and AIR CONDITIONING
19A
6 7
108627
Remove bolts (4). Remove the bumper unit (this operation requires two workers). Disconnect the fog light connector (if fitted to vehicle). Remove the air filter unit air intake tube. DIRECTION ASSISTEE Disconnect the power assisted steering pipe from the fan assembly. Remove the power assisted steering fluid reservoir from its mountings (without opening the circuit), Secure the power assisted steering fluid reservoir to the engine. Disconnect: - fan assembly connectors ( 5). - the upper radiator hose using tool (Mot. 1202-01) or (Mot. 1448). Unclip the fan assembly: - the electric wiring harness, - air conditioning pipe (6 ). DIRECTION ASSISTEE Remove bracket (7) for the power assisted steering fluid reservoir.
109396
19A-10

19A
10
108104
Remove: - mounting pins (8) from the air deflector, - the air deflector.
108430
Remove radiator mounting nuts ( 10). Remove: - the upper radiator mounting brackets, - the fan assembly, - the radiator.
REFITTING
9
WARNING
108106
Ensure that the ns of the cooling radiator and the condenser are not damaged as they are removed. Fill and bleed the cooling circuit (see 19A, Cooling, Draining - Filling the cooling circuit).
9
108107
Remove condenser mounting bolts (9) from the radiator. Attach the condenser to the upper cross member.
19A-11

K7J or K7M, and 710, and BASIC HEATING Essential special tooling Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Remote operation pliers for cooling system hose clips
19A
Mot. 1448
REMOVAL
Mount the vehicle on a lift. Remove the engine undertray. Drain the cooling circuit via the lower radiator hose using tool (Mot. 1202-01) or (Mot. 1448) (see 19A, Cooling, Draining - Filling the cooling circuit).
109398
DIRECTION ASSISTEE Remove the power assisted steering fluid reservoir from its mountings (without opening the circuit), Attach the power assisted steering fluid reservoir to the engine.
Disconnect: - the upper radiator hose using tool (Mot. 1202-01) or (Mot. 1448), - fan assembly connector ( 2).
3 1
108430
109396
Remove radiator mounting bolts ( 3) through the radiator grille (without removing the bumper). Remove the radiator.
Remove bracket (1) for the power assisted steering fluid reservoir.
19A-12

K7J or K7M, and 710, and BASIC HEATING
19A
REFITTING
Proceed in the reverse order to removal. WARNING Ensure that the ns of the cooling radiator are not damaged as it is removed. Fill and bleed the cooling circuit (see 19A, Cooling, Draining - Filling the cooling circuit).
19A-13
COOLING SYSTEM Water pump

K7J, and 710 Essential special tooling Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Remote operation pliers for cooling system hose clips - the water pump.
19A
CLEANING
Mot. 1448
IMPORTANT - Do not scratch the aluminium sealing surfaces. - Wear goggles. - Wear gloves during the operation.
Tightening torques m water pump M8 bolt water pump M6 bolts 2.2 daNm 1 daNm
- Clean the sealing surfaces with DECAJOINT to dissolve off any part of the seal still attached. - Apply the product to the section to be cleaned; Wait approximately ten minutes, then remove the residue using a wooden spatula.
REMOVAL
Disconnect the battery, starting with the negative terminal. Drain the coolant circuit via the lower radiator hose using tool (Mot. 1202-01) or tool (Mot. 1448) (see 19A, Cooling, draining and filling the coolant circuit). Remove: - the timing belt (see 11A, Top and front of engine: Timing belt), - the timing tension wheel.
REFITTING
10063
Note: The water pump is sealed using LOCTITE 518. A line (1 ) must be applied according to the diagram above.
109240
Remove: - the water pump mounting bolts,
19A-14

K7J, and 710
19A
1 4 3 5
6 7
8 2
109240
Torque tighten in order: - the water pump M8 bolt (2.2 daNm),(1) - the water pump M6 bolts (1 daNm) . Remove the timing belt (see 11A, Top and front of engine, Timing belt). Fill up and bleed the cooling circuit (see 19A, Cooling, Draining - Filling the cooling circuit).
19A-15

K7M, and 710 Essential special tooling Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Remote operation pliers for cooling system hose clips - the water pump.
19A
CLEANING
Mot. 1448
IMPORTANT - Do not scratch the aluminium sealing surfaces. - Wear goggles. - Wear gloves during the operation.
Tightening torques m water pump M8 bolt water pump M6 bolts 2.2 daNm 1 daNm
- Clean the sealing surfaces with DECAJOINT to dissolve off any part of the seal still attached. - Apply the product to the section to be cleaned; Wait approximately ten minutes, then remove the residue using a wooden spatula.
REMOVAL
Disconnect the battery, starting with the negative terminal. Drain the coolant circuit via the lower radiator hose using tool (Mot. 1202-01) or tool (Mot. 1448) (see 19A, Cooling, draining and filling the coolant circuit). Remove: - the timing belt (see 11A, Top and front of engine: Timing belt), - the timing tension wheel.
REFITTING
10063
Note: The water pump is sealed using LOCTITE 518. the cordon ( 1) must be applied according to the diagram above.
109240
Remove: - the water pump mounting bolts,
19A-16

K7M, and 710
19A
1 4
6 7
3 5 2
109240
Torque tighten in order: - the water pump M8 bolt (2.2 daNm),(1) - the water pump M6 bolts (1 daNm) . Remove the timing belt (see 11A, Top and front of engine, Timing belt). Fill up and bleed the cooling circuit (see 19A, Cooling, Draining - Filling the cooling circuit).
19A-17
COOLING SYSTEM Thermostat

K7J or K7M, and 710 Essential special tooling Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Remote operation pliers for cooling system hose clips
19A
Mot. 1448
Tightening torques m thermostat support unit mounting bolts 1 daNm
REMOVAL
Drain the coolant circuit via the lower radiator hose using tool (Mot. 1202-01) or tool (Mot. 1448) (see 19A, Cooling, draining and filling the coolant circuit). Remove the air filter unit air intake tube.
109212
Remove: - the mounting bolts from the thermostat support unit, - the thermostat support unit, - the thermostat.
REFITTING
1
The thermostat support unit seal must always be replaced. Proceed in the reverse order to removal. Torque tighten the thermostat support unit mounting bolts (1 daNm).
2
108565
Remove hoses (1) from thermostat support unit (2).
19A-18
COOLING SYSTEM Engine cooling fan assembly

K7J or K7M, and 710, and BASIC HEATING - the fan assembly. Essential equipment IF REPLACING diagnostic tool Remove:
19A
Tightening torques m fan assembly mounting bolts 0.4 daNm
- the retaining clip for the hose connecting the power assisted steering to the fan assembly (if fitted to the vehicle), - the mounting clip for the wiring harness on the fan assembly.
REMOVAL
Disconnect the battery, starting with the negative terminal. Remove the air intake sleeve. DIRECTION ASSISTEE Unclip the power assisted steering hose from the fan assembly. Remove the power assisted steering fluid reservoir from its support (without opening the circuit). Connect the power assisted steering fluid reservoir to the engine.
REFITTING
Proceed in the reverse order to removal. Torque tighten the fan assembly mounting bolts (0.4 daNm). WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery, Battery: Remove and ret ). CHECKING OPERATION OF THE FAN ASSEMBLY Start the engine. Disconnect the coolant temperature sensor (see 17B, Petrol injection, Location of components). Check operation of the fan assembly. Reconnect the coolant temperature sensor connector. Turn the engine off. Use the diagnostic tool to clear fault code DF004 coolant temperature sensor circuit : - read the fault codes, - carry out any necessary repairs, - clear the fault codes.
1
109398
Disconnect fan assembly connector (1). Unclip the wiring harness on the fan assembly. Remove: - the fan assembly mounting bolts,
19A-19

19A
2
REMOVAL
1
DIRECTION ASSISTEE Remove the air intake sleeve. Unclip the power assisted steering hose from the fan assembly. Remove the power assisted steering fluid reservoir from its support (without opening the circuit). Connect the power assisted steering fluid reservoir to the engine. Disconnect fan assembly connectors (1 ). Note: Mark the connectors to avoid retting them incorrectly. Unclip the following from the fan assembly: - the electric wiring harness, - air conditioning pipe (2 ). Remove the fan assembly. IF REPLACING Remove: - the retaining clip for the hose connecting the power assisted steering to the fan assembly (if fitted to the vehicle), - the fan assembly resistor, - the mounting clip for the wiring harness on the fan assembly.
109396
REFITTING
Proceed in the reverse order to removal. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery, Battery: Remove and Ret).
19A-20

K7J or K7M, and 710, and AIR CONDITIONING CHECKING OPERATION OF THE FAN ASSEMBLY Start the engine. Disconnect the coolant temperature sensor (see 17B, Petrol injection, Location of components). Check operation of the fan assembly. Reconnect the coolant temperature sensor connector. Turn the engine off. Use the diagnostic tool to clear fault code DF004 coolant temperature sensor circuit : - read the fault codes, - carry out any necessary repairs, - clear the fault codes.
19A
19A-21
EXHAUST General information

K7J or K7M, and 710 The catalytic converter reaches high temperatures; do not park the vehicle close to flammable materials. Cut zone 2
19B
WARNING - All damaged heat shields must be replaced. - The seal between the exhaust manifold gasket face and the catalytic converter (inclusive) must be perfect. - All removed seals must be replaced. - The catalytic converter must not be subjected to mechanical impact during removal or retting, as this could damage it.
108927
SPECIAL NOTES ON THE EXHAUST PIPE

X2
1 - Exhaust pipe cutting line The exhaust pipe is a single unit type. When replacing one of the components, cut the exhaust pipe. It is essential: - to identify the area to be cut correctly, - to use the cutting tool correctly (Mot. 1199-01), - to position the after sales sleeve correctly.
2 - Illustration of the area to be cut

100649
Two marks on the exhaust pipe define the area to be cut (see 19A, Exhaust, Pipe assembly).
Before cutting the pipe, mark the midpoint between the two marks. The distance between the two marks is (X2) = 80 mm.
Cut zone 1
108351
19B-1
EXHAUST General information

K7J or K7M, and 710 3 - Operate tool Mot. 1199-01
19B
X1
102118
Position the tool on the pipe. Tighten the bolts on the cutting tool so that it grips the pipe. Turn the cutting tool with the handle while gripping the pipe. As the cut is made, continue to tighten the bolts on the tool (do not overtighten the tool on the pipe, to avoid distortion during the cutting operation). 4 - Fitting the after-sales sleeve
100649
To prevent any exhaust leak, position the sleeve correctly on the two lugs (3 ) and apply some exhaust MASTIC (see 04B, Consumable products, Conditioning) to the inside of the sleeve: - slide on the sleeve fully, positioning it on the lugs (3) on the old part of the pipe, - adjust the sleeve diameter by tightening gently, - mount the new component fully onto the lugs (3).
WARNING Make sure: - that the sleeve tightening nut - bolt assembly is vertical, with the nut facing downwards, to prevent any risk of underbody contact, - to adjust the new component so that the cut zone marks are aligned (X1 ), - that the two marks are ush with both sides of the sleeve.
- Do not reuse an old sleeve. Torque tighten the sleeve tightening nut (2.5 daNm).
95478
19B-2
EXHAUST Pipe assembly

K7J, and 710
19B
109861
( 1) ( 2)
Cut zone 1 Cut zone 2
19B-3
EXHAUST Pipe assembly

K7M, and 710
19B
109861
( 1) ( 2)
Cut zone 1 Cut zone 2
19B-4
EXHAUST Catalytic converter

K7J, and 710 Essential special tooling Mot. 1199-01 Mot. 1495 Exhaust pipe cutter 22 mm oxygen sensor removal / retting socket - 1/2" square drive and a 24 mm Allen key
19B
1
Tightening torques m oxygen sensor catalytic c o nverter mounting nuts 4.5 daNm 2.1 daNm
108351
REMOVAL
IMPORTANT Catalytic converters contain ceramic bres; these are contained within a closed unit, and cannot be dispersed. Drilling or cutting catalytic converters is prohibited. Mount the vehicle on a lift. Remove the engine undertray.
14747
Cut the exhaust pipe using tool (Mot. 1199-01) between the two cutting points ( 1).
108424
Slide out the oxygen sensor connector to remove it from its support (as shown by the arrow). Disconnect the oxygen sensor connector.
19B-5

K7J, and 710
19B
REFITTING
109399
WARNING
107926
Remove: - the catalytic converter mountings from the exhaust manifold, - the catalytic converter. IF REPLACING THE CATALYTIC CONVERTER Remove the oxygen sensor from the catalytic converter.
Be sure to replace the sealing ring between the exhaust manifold and the catalytic converter. Refit the oxygen sensor. Tighten to torque the oxygen sensor (4.5 daNm) using tool (Mot. 1495). Mount: - the catalytic converter, - the sleeve (see 19A, Exhaust, General information). Torque tighten the catalytic converter mounting nuts (2.1 daNm). Tighten the sleeve while supporting the exhaust pipe to ensure they are aligned. Proceed in the reverse order to removal.
19B-6

K7M, and 710 Essential special tooling Mot. 1199-01 Mot. 1495 Exhaust pipe cutter 22 mm oxygen sensor removal / retting socket - 1/2" square drive and a 24 mm Allen key
19B
1
Tightening torques m oxygen sensor catalytic c o nverter mounting nuts 4.5 daNm 2.1 daNm
108351
REMOVAL
IMPORTANT Catalytic converters contain ceramic bres; these are contained within a closed unit, and cannot be dispersed. Drilling or cutting catalytic converters is prohibited. Mount the vehicle on a lift. Remove the engine undertray. Disconnect the oxygen sensor connector. Cut the exhaust pipe using tool (Mot. 1199-01) between the two cutting points ( 1).
14747
108424
Slide out the oxygen sensor connector to remove it from its support (as shown by the arrow). Disconnect the oxygen sensor connector.
19B-7

K7M, and 710
19B
REFITTING
109399
WARNING
107926
Remove: - the catalytic converter mountings from the exhaust manifold, - the catalytic converter. IF REPLACING THE CATALYTIC CONVERTER Remove the oxygen sensor from the catalytic converter.
Be sure to replace the sealing ring between the exhaust manifold and the catalytic converter. Refit the oxygen sensor. Tighten to torque the oxygen sensor (4.5 daNm) using tool (Mot. 1495). Fit: - the catalytic converter, - the sleeve (see 19A, Exhaust, General information). Torque tighten the catalytic converter mounting nuts (2.1 daNm). Tighten the sleeve while supporting the exhaust pipe to ensure they are aligned. Proceed in the reverse order to removal.
19B-8
EXHAUST Expansion chamber

K7J or K7M, and 710 Essential special tooling Mot. 1199-01 Exhaust pipe cutter
19B
REMOVAL
Mount the vehicle on a lift.
2 1
108927
Use tool (Mot. 1199-01) to cut the exhaust pipe in the centre of area to be cut (2 ). Remove the expansion chamber.
REFITTING
108351
Mount: - the expansion chamber, - the sleeves (see 19B, Exhaust, Vehicle Specification ). Tighten the sleeve while supporting the exhaust pipe to ensure correct alignment. Proceed in the reverse order to removal.
14747
Use tool (Mot. 1199-01) to cut the exhaust pipe in the centre of area to be cut (1).
19B-9
EXHAUST Silencer
K7J or K7M, and 710 Essential special tooling Mot. 1199-01 Exhaust pipe cutter
19B
REMOVAL
Mount the vehicle on a lift.
108927
Use tool (Mot. 1199-01) to cut the exhaust pipe in the centre of area to be cut (1). Remove the silencer.
REFITTING
Mount: - the silencer, - the sleeve (see 19B, Exhausts, Vehicle specification ). Tighten the sleeve while supporting the exhaust pipe to ensure correct alignment. Proceed in the reverse order to removal.
19B-10
RESERVOIR Draining the fuel tank

19C
3
IMPORTANT During this operation, be sure to: - refrain from smoking or bringing hot objects close to the work area, - beware of fuel splashes when disconnecting the union, - protect sensitive areas from fuel outow.
109173
Connect: - T union (Mot. 1311-08)(3 ) to the pipe coming from the fuel tank,
- pipe ( 2 ) contained in test kit (Mot. 1311-01) to T union ( 3). Place end of pipe ( 2) in a container. IMPORTANT This procedure must be carried out with the ignition off.
108650
Disconnect fuel supply pipe union (1). IMPORTANT Wear gloves during the operation.
19C-1
RESERVOIR Draining the fuel tank

K7J or K7M, and 710
19C
109171
Disconnect engine/passenger compartment wiring harness (4).
109172
Connect connector terminal (5) to + battery feed to operate the fuel pump. Allow the fuel to run out until the flow is intermittent. Disconnect the + battery feed from terminal (5).
19C-2
RESERVOIR Fuel tank

K7J or K7M, and 710
19C
Tightening torques m fuel tank mounting bolts to torque catalytic c o nverter mounting nuts 2.1 daNm 2.1 daNm
REMOVAL
Mount the vehicle on a two-post lift. Drain the fuel tank (see 19C, Fuel tank, Draining the fuel tank). Disconnect the battery, starting with the negative terminal.
108525
108524
Open the two rear doors. Remove the seat base from the rear bench seat.
19C-3
RESERVOIR Fuel tank

K7J or K7M, and 710
19C
109177
109185
Remove the flap in the floor panel providing access to the pump/gauge/filter assembly. Disconnect the fuel pump connector.
Remove body earth cable (2 ).
3
109183
Remove: - heat shield attachment pins, - the heat shield. Remove the engine undertray.
108652
Remove the filler neck mounting bolts (1).
19C-4
RESERVOIR Fuel tank

K7J or K7M, and 710
19C
108650
Disconnect the fuel pipes coming from the fuel tank.
IMPORTANT
108424
Remove the oxygen sensor connector by sliding it from its support (in the direction of the arrow). Disconnect the oxygen sensor connector.
During this operation, be sure to: - refrain from smoking or bringing hot objects close to the work area, - beware of fuel splashes when disconnecting the union, - protect sensitive areas from fuel outow.
109181 107926
Unclip the cables connecting the parking brake to: - the fuel tank, - the body. Remove: - the fuel tank mounting bolts, - the fluid reservoir.
Remove the nuts mounting the catalytic converter on the exhaust manifold. Unhook the exhaust line assembly from the body. Place the exhaust line assembly on the left-hand side. Attach the front section of the exhaust line assembly to the front lower arm on the left-hand side.
19C-5
RESERVOIR Fuel tank

K7J or K7M, and 710
19C
REFITTING
Refit the fuel tank. Tighten the fuel tank mounting bolts to torque (2.1 daNm).
109399
WARNING It is essential to replace the sealing ring between the exhaust manifold and the catalytic converter. Refit the exhaust line assembly. Torque tighten the catalytic converter mounting nuts (2.1 daNm). Proceed in the reverse order to removal. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery, Battery: Remove and Ret).
19C-6
RESERVOIR Pump / sender unit / filter

K7J or K7M, and 710 Essential special tooling Mot. 1397 Universal spanner for removing fuel gauge nut
19C
IMPORTANT During this operation, be sure to: - refrain from smoking or bringing hot objects close to the work area, - beware of fuel splashes when disconnecting the union, - protect sensitive areas from fuel outow.
REMOVAL
108525
108524
Open the two rear doors. Remove the seat base from the rear bench seat.
19C-7

K7J or K7M, and 710
19C
109177
109176
Remove the flap providing access to the pump/gauge/filter assembly. Disconnect: - the fuel pump connector, - the pipe to the pump/gauge/filter assembly.
Remove the locking ring from the pump/gauge/filter assembly using tool (Mot. 1397). Allow the fuel in the pump/gauge/filter assembly to run out. Remove the pump/gauge/filter assembly, being careful not to damage the float. WARNING If several hours are to pass between the pump/ gauge/ lter assembly being removed and retted, tighten the locking ring on the fuel tank to prevent any damage.
19C-8

K7J or K7M, and 710
19C
REFITTING
109179 109180
It is essential to replace O-ring (1). WARNING Make sure that the seal is positioned correctly when the pump/gauge/lter assembly is retted. Refit the pump/gauge/filter assembly.
Tighten the locking ring on the pump/gauge/filter assembly using tool (Mot. 1397). WARNING The pump/gauge/ lter assembly index and locking ring index must be between the two markings on either side of the fuel tank index. Proceed in the reverse order to removal. WARNING Connect the battery, starting with the positive terminal; carry out the necessary programming (see 80A, Battery, Battery: Remove and Ret).
19C-9
RESERVOIR Fuel level sensor: Distinctive

K7J or K7M, and 710 The fuel pump, the fuel filter and sender form an inseparable assembly. I -CONNECTING THE PUMP/GAUGE/FILTER ASSEMBLY
19C
Refit the pump/gauge/filter assembly (see 19C, Fuel tank, Pump/gauge/filter ).
A1
B1
C1
C2
108538
For information on connecting the pump/gauge/filter unit (see Technical Note Wiring diagrams, component 199 ). II - CHECKING THE GAUGE SENDER UNIT Remove the pump/gauge/filter assembly (see 19C, Fuel tank, Pump/gauge/filter).
Height H (mm) 148 109 82 54 24 Measuring the height H:
Value across terminals A1 and B1 () 33 +8/-2 110 9 166 9 232 10 313 +5/-10
- place the pump/gauge/filter assembly on a work surface, - measure height H between the float pivot and the work surface.
19C-10
ENGINE MOUNTING Suspended engine mounting

K7J, and 710
19D
4
1 3
109231
Reference 1 2 3 4
Tightening torque in daNm 10.5 6.2 6.2 10.5
19D-1
ENGINE MOUNTING Suspended engine mounting

K7M, and 710
19D
4
1 3
109231
Reference 1 2 3 4
Tightening torque in daNm 10.5 6.2 6.2 10.5
19D-2

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1

Engine and assembly

Renault s.a.s. 2004

Renault s.a.s. 2004

L90 - Section 1 ContentsPage

ANTIPOLLUTION Petrol vapour rebreathing: Operation

14A-1 14A-2 14A-3 14A-4

16A-1 16A-2 16A-12 16A-13

IGNITION coils Spark plugs 17A-1 17A-5

RESERVOIR Draining the fuel tank 19C-1 19C-3 19C-7 19C-10

17B-31 17B-32 17B-33 17B-34 17B-35 19D

ENGINE MOUNTING Suspended engine mounting 19D-1

ENGINE AND LOWER ENGINE ASSEMBLY Oil filter

REPLACING THE OIL FILTER

ENGINE AND LOWER ENGINE ASSEMBLY Oil filter

REPLACING THE OIL FILTER

ENGINE AND LOWER ENGINE ASSEMBLY Oil consumption

1 - Filling to the maximum level

ENGINE AND LOWER ENGINE ASSEMBLY Oil pressure

Special tooling required Mot. 36-05 Oil pressure gauge kit

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

10.5 daNm 2.1 daNm 6.2 daNm 10.5 daNm

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

DIRECTION ASSISTEE, and BASIC HEATING

Remove the power assisted steering pipe mounting bolts:

Remove the power assisted steering high-pressure pipe.

Disconnect connector (10) of the power assisted steering pressure switch.

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

DIRECTION MANUELLE, and AIR CONDITIONING

DIRECTION ASSISTEE, and AIR CONDITIONING

Disconnect fan assembly connectors (12) .

Disconnect connectors (14) of the fan assembly.

Disconnect connector (15) of the power assisted steering pressure switch.

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

Disconnect connector (17) of the refrigerant pressure sensor.

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

Disconnect cooling hoses (22).

Remove cooling hoses (23) from their support.

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

Remove rubber protection (31) from the gear lever.

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

Remove: - the suspended engine mounting cover mounting bolts,

- the suspended mounting from engine (33) .

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

Place tool (Mot. 1390) under the sub-frame.

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

10.5 daNm 2.1 daNm 6.2 daNm 10.5 daNm

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

DIRECTION ASSISTEE, and BASIC HEATING

Remove the power assisted steering pipe mounting bolts:

Remove the power assisted steering high-pressure pipe.

Disconnect connector (10) of the power assisted steering pressure switch.

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly

DIRECTION MANUELLE, and AIR CONDITIONING

DIRECTION ASSISTEE, and AIR CONDITIONING

Disconnect fan assembly connectors (12) .

Disconnect fan assembly connectors (14) .